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978-93-84893-67-5
Chapter - 1
V -b elt
F la t b elt C ircula r b elt
. . .. . . .
. . .. ..
. .. ..............
..
(ii) V - belts
The V - belt as shown in Fig.1.1(b) are generally
endless and their cross-section shape is trapezoidal. The V
- shape of belt tracks in a mating groove in the shaft, with
the result that the belt cannot slip off.
D rive r
Slack side D rive n
e
T ig h t s id
D rive r
S la D rive n
ck s
id e
+ +
id e
ht s
T ig
D rive r
D rive n
G uide pulle y
(a) Q uarter Turn Belt Drive. (b) Q uarter Turn Belt Drive
with Guide Pulley.
Fig.1.4
D rive r
3
4
1
2 + Fo llow er
+ +
3 4
1 2
Fig. 1.5. C om pou nd Belt Drive.
Design of Flexible Elements 1.7
+
Idler
pulleys
D rive r
+ + D rive n
Pu lleys
+
+
+ +
Idler pulley
Fig.1.6 (b). Belt Drive with Single Idler Pulley
1.8 Design of Transmission Systems
D riving pu lley
M ain o f L ine s ha ft
D riving Sh aft
C o ne pu lley
L oo se p ulley
Fa s t p ulley
d D
N1
N2
(D river)
C (D riven)
Fig.1.9
N 1 speed of driver
N 2 speed of driven
Step 1
N2 d
Velocity ratio
N1 D
dt
Dt t thickness of belt
(If thickness is considered)
dt S
1
D t 100 (where S % of slip)
1
Speed ratio
Velocity ratio
N1 D
N2 d
Step 2
Ratio of tensions
T1 Tc
e
T2 Tc
coefficient of friction
angle of contact in radians
Rr
2 where sin 1
C
deg R larger pulley radius
180
1.10 Design of Transmission Systems
density of where,
volume
bel t material density in kg/m 3
Area length A Area in m 2 b t
A l kgf/m length length 1 m assume
b width of belt in m
t thickness of belt
in m
If is given in kg/cm 3, then assume A in cm 2 and
length 100 cm.
dN 1 DN 2
or m/sec
60 60
Step 4
T T1 Tc
Step 5
Power transmitted by the belt
Also P T 1 T 2 v in watts
T
v [velocity of belt for m ax. pow er.]
3m
Step 6
T1 T2
T0
2 (if Tc is neglected)
T1 T2 2T c
T0
2 (if Tc is considered)
1.12 Design of Transmission Systems
Step 7
Length of Open belt drive.
D d2
L D d 2C
2 4C
D larger pulley dia.
Length of Cross belt drive
d smaller pulley dia.
2
D d C Centre distance
L D d 2C
2 4C
(or)
D N1
Speed ratio
d N2
D d
Arc of contact 180 60
C
where
C Centre distance
v
= Load rating number of plies
10 180
1.14 Design of Transmission Systems
(or)
corrected load
Width of belt
load rating/mm
D d2
L 2C D d
2 4C
D d2
L 2C D d
2 4C
L
2
D d
2
C2 D C2
d2
N 2 500 rpm ;
C 2 metre 2 10 3 mm ; D 750 mm
N2 d
Velocity ratio
N1 D
dN 1
Velocity of belt v
60
250 1500
19.63 m sec
60 1000
Dd
Arc of contact 180 60
C
750 250
180 60
2000
165
K 1.06
K
160 1.08
5 0.02
165 1.06
1.3 10
12.26 kW
1.06
Take, n n o. of plies 5
0.023 19.63
10
0.0451 kW mm ply
12.26
Width no. of plies 271.54
0.04515
271.54
Width of the belt 54.3 mm
5
D d2
L D d 2C
2 4C
750 2502
L 750 250 2 2000
2 4 2000
5602.04 m m
Width of Pulley
Refer PSG data book, Page No. 7.54
width of pulley 76 13 89 mm
Given Data
t 9 mm 0.9 cm ; b 250 mm 25 cm ; d 90 cm
N 338 rpm; 120 2.094 radian
180
20 0.9 25 450 kg
2.205 15.928 2
55.940 N
55.94 kg
dN
v
60
90 338
100 60
v 15.9278 m /sec
450 55.94
394.05 kg
1
Power capacity of the belt P T1 Tc 1 v
e
1
394.05 55.94 1 15.9278
0.35 2.094
e
1.20 Design of Transmission Systems
27987.69
kgf m/sec 75 kgf m sec 1 HP
75
P 37.30 HP
Problem 1.3: Two parallel shafts whose centre lines are 4.8
m apart, are connected by an open belt drive. The diameter of
the larger pulley is 1.5 m and that of smaller pulley 1.05 m.
The initial tension in the belt when stationary is 3 kN. The
mass of the belt is 1.5 kg m length. The coefficient of friction
between the belt and the pulley is 0.3; Taking centrifugal
tension into account, calculate the horse power transmitted,
when the smaller pulley rotates at 400 rpm. (Oct. ’99)
T0 3 kN 3 10 3 N
T 1 T 2 2Tc
Initial tension T 0 3 10 3
2
1.5 21.99 2
725.41 N
T 1 T 2 3 10 3 2 2 725.41
T 1 T 2 4549.18 N 1
From open belt drive
Angle of contact 2
2 2.68 174.64
180
3.048 radia
,n
d N 1
Velocity of the belt v
60 100
1.05 400
60
21.99 m s ec
T1 T1
e; e0.3 3.048 2.495
T2 T2
T1 2.495 T 2
2.495 T2 T2 4549.18
4549.18
T1 1301.6 N
3.495
Given Data
Power P 10 kW;
Centre distance C 2 m
Solution
N2
D d
N1
1200
300
450
800 mm
D 800 mm
0.3 1200
60
18.84 m/s
Design of Flexible Elements 1.23
K s 1.3
Dd
Arc of contact 180 60
c
0.8 0.3
180 60
2
165
10 1.3
1.06
12.26 kW
v
L oad rating number of plies
10 180
18.84 165
0.023 6
10 180
0.2383 kW/mm
12.26
0.2383
D d2
L 2C D d
2 2C
0.8 0.32
22 0.8 0.3
2 22
5.79 m 5790 mm
Given Data
Diameter of pulley D 900 mm 0.9 m
63 10 6 N/m 2
1.26 Design of Transmission Systems
Solution
We know that,
0.9 200
60
v 9.42 m/s
7500
T1 T2
9.42
T1 T2 796.17 N
Given that,
T 1 2T2
2T2 T 2 796.17
T 2 796.17 N
and
T 1 1592.35 N
Design of Flexible Elements 1.27
1592.35
145 /10 . .
. 145 N in 10 mm width
14.5 / mm width
109.81 mm
2 NT
Since, power
60
60P
Torque T
2 N
60 7500
2 200
358 Nm
16T
d3
1/3
16 358
d 6
0.030702 m
63 10
Dimensions of pulley
(a) Dimensions of rim
112 13
125 mm
Thickness of arm
(i) Thickness of arm near the boss (b)
aD
4n
3
b 2.94 for single belt
Design of Flexible Elements 1.29
125 900
3
b 2.94 49.20 mm
46
Given
P 1.1 kW 1.1 10 3 W
C 1.2 m 1.2 10 3 mm
N 1 350 rpm
N 2 140 rpm
D 400 mm
Solution
Step 1: Diameter of driven pulley
N2 d
Velocity ratio
N1 D
d 140
400 350
d 160 mm
1.30 Design of Transmission Systems
d 160 mm
160 350
60 1000
v 2.93 m/s
K s 1.2
Dd
Arc of contact 180 60
C
400 160
180 60
1200
168
K 1.04
Design of Flexible Elements 1.31
1.2 1.1
1.04
1.26 kW
C orrected power
Millimeter piles of belt
Load rating/mm/ply
Corrected power
Width Number of piles
Load rating/mm/ply
1.26
Width
0.006289 Number of piles
186.97
Width
Number of piles
186.97
Width 46.74 mm
4
D d2
L 2C D d
2 4C
400 1602
2 1200 400 160
2 4 1200
3291.6 mm
L 3300 mm
Wid th of pulley 63 mm
Given
D 430 mm 0.43 m R 0.215 m
0.25
Solution
Since length of the flat belt is given from P.S.G Data
book Pg.No. 7.53 for cross drive
D d2
L 2C D d
2 4C
0.43 0.182
2 1.9 0.43 0.18
2 4 1.9
L 4.8071 m 4807.1 mm
Rr
where sin 1
C
0.215 0.09
sin 1
1.9
9.237
180 2 9.237
198
198 3.464 rad
180
P T 1 T2 v
DN 1 0.43 210
But v
60 60
4.72 m/s
T1
But e and T1 1000 N
T2
1000
e0.25 3.464
T2
T 2 420.63 N
2734.62 W
P 2.734 kW
Design of Flexible Elements 1.35
Given
d 40 c m 0.4 m; D 160 cm 1.6 m;
To find
Since
d N1 DN 2
(or)
60 60
0.4 700
v
60
v 14.7 m /s
T1 T 2
P v
75
T1 T 2
30 14.7
75
1.36 Design of Transmission Systems
T1
2.11
T2 ...(2)
From equations (1) and (2)
2.11 T 2 T2 153.06
T 2 137.89 kg f
and T1 290.95 kg f
0.05 b kg/m
w
Tc v2
g
0.05 b
14.71 2
9.81
Tc 1.1b kgf
T T1 Tc stress Area
T T1 Tc bt
b 27.88 cm ~
28 cm
Solution
1.38 Design of Transmission Systems
d 1N 1 S1
v 1
60 100
0.9 N1 1.2
20 1 100
60
N 1 430 rpm
d 2N 2 S2
v1
60 100
1.2 N 2 1.2
20 1
60 100
N 2 315 rpm
150 4500
2 315
341 kg f m
Design of Flexible Elements 1.39
0.6 T 1 T 2 Kg f m
430
T 1 T 2 717 kg f
0.6
O 2M r2 r1 60 45
sin 0.0417
O 1O 2 x 360
2.4
1.40 Design of Transmission Systems
175.2 3.06 rad
180
We know that
T1
T e
2
e0.3 3.06
T1 0.918
e
T2
T1
or 2.51
T2 ...(2)
From equations (1) and (2), we have
b 1.5 1000 1
0.15 b kg/m
Design of Flexible Elements 1.41
w
Tc v2
g
0.15b
202
9.81
6.12b kgf
T T1 Tc f.b.t
b 37.98 cm
d 2 d 12
L 2x d 2 d1
2 4x [x C centre distance]
120 902
2 360 120 90
2 4 360
1050.6 c m
L 10.506 m
Given Data
P 20 kW; N 1 780 rpm ; i 3; C 2.8 m ; D 1.4 m
Solution
Step 1: Diameter of Driver pulley
We know that
D N1
Speed ratio i
d N2
D 1.4
d 0.466 m
i 3
0.466 780
60
19.03 m/s
Step 3: Load correction factor K s
From PSG Data book Pg.No. 7.53;
Load correction factor k s 1.5 (for rolling machine)
Dd
Arc of contact, 180 60
C
1.4 0.466
180
2.8
159.98 ~
160
160
Design of Flexible Elements 1.43
1.5 20
1.08
19.03 160
0.0289 6
10 180
Corrected load
loa d rating/mm/ply at belt spe ed
b 94.44 mm
D d2
Belt length L 2C D d
2 4C
1.4 0.466 2
L 2 2.8 1.4 0.466
2 4 2.8
8.608 m
b 177 mm
1.2.2 Advantages
1. High velocity ratio (upto 7 and in some cases 10
also)
2. Smaller centre distance.
1.46 Design of Transmission Systems
1.2.3 Disadvantages
1. Design of V-belt drive is more complicated.
2. Cannot be used for larger centre distance.
x
tan 20
T
x T tan 20
b W 2x
W 2 T tan 20
DESIGN OF V-BELTS
1
Power transmitted per beltP T 1 T c 1 v
/sin
e
Total power transmitted
n Number of V belts
Power trans mitted per b elt
*Step 1
*Step 2
Step 3
D d2
L D d 2C
2 4C
d1 N 1
where S belt speed m/sec
60
de equivalent pitch diameter
dp Fb
D
Take value of F b at ratio.
d
N 1 driven dia D
Speed ratio
N driver dia d
2
*To Find No. of belts
Refer PSG Data book Page No. 7.70
P Fa
No. of belts n
kW F c fd
where P given power in kW
F c Correction factor for length Refer data book Page No. 7.59 and 7.60
F d Correction factor for arc of contact Refer data book Page No. 7.68
Dd
180 60 C given ce ntre distance.
C
at value, take F d
CA A2 B
L Dd
where A
4 8
D d2
B
8
*Calculation of T 1 and T 2
T1 Tc
e /sin
T2 Tc ... (1)
SemiGroove a ngle
Dd
Arc of contact 180 60
C
C alculate in radians.
Centrifugal tension Tc m v2
(C.S. must be in m 2)
d N1
v m/sec
60
(or)
Tc m v2 Newton.
T 1 T c fb area of belt
Calculate fb:
T1 T2
* Initial tension T o
2
1.52 Design of Transmission Systems
Given data:
P 30 103 Watts
C 1440 mm
1.44 m
Step 1
1
C.S. area of belt W b T
2
1
[22 11.81 ] 14
2
236.67 mm2
Step 2
D d2
Nominal pitch length L D d 2C
2 4C
750 2202
750 220 2 1440
2 4 1440
4452.439 mm
.
4.452 m
Take the nearest nominal pitch length from PSG data
book.
Refer PSG data book P.No. 7.60,
142.7
kW 1.47S 0.09 2.34 10 4S2 S
de
[S v velocity]
1.54 Design of Transmission Systems
220 mm
D 750
3.4
d 220
0.09 142.7 4 2
kW 1.47 16.587 2.34 10 16.587 16.587
250.8
P 8.4312 kW
Step 4
To find the no. of belts (n)
Refer PSG Data book page No. 7.70
P Fa
No. of belts n
kW F c F d
where
P given po wer kW
Dd
180 60
C
750 220
180 60 157.9
1440
158
CA
A2 B (from PSG Data book P.No. 7.61)
750 2202
B 35112.5 mm
8
Calculation of T 1 and T 2
T1 Tc 2 40
e /sin ... (1)
T2 Tc Semi-groove angle 20
Let 0.25
158
180
2.75 radians
1
Power/belt [T 1 T c] 1 v
/sin
e
1
8.3412 10 3 T1 94.36 1 16.587
0.25 2.75 / sin 20
e
T 1 681.3274 N
Design of Flexible Elements 1.57
T1 Tc
e/sin
T2 Tc
681.3274 94.36
e0.25 2.75/sin 20
T 2 94.36
5869619
7.464
T2 94.36
T 2 78.638 94.36
T 2 172.998 N
fb 3.28 N/mm 2
Given Data:
P 75 10 3 Watts
1.58 Design of Transmission Systems
Service 16 hr/day .
Step 1
Selection of Cross section;
Nominal Width W 22 mm
Nominal thickness t 14 mm
1
C.S. area W b t
2
1
[22 11.808] 14 236.656 mm 2
2
Step 2
D d2
Nominal Pitch length L D d 2C
2 4C
1050 3002
1050 300 2 2500
2 4 2500
7176.82 mm
L 7.176 m
Design of Flexible Elements 1.59
N1 D
N2 d
N1 1440
D d 300 1050 m m
N2 400
Take the nearest value of nominal pitch length (from PSG
data book 7.60) L 6863 mm
142.7
kW 1.47 22.61 0.09 2.34 10 422.612 22.61
300
1.60 Design of Transmission Systems
Step 4
P Fa
No. of belts n
kW Fc F d
P 75 kW
F a 1.2
P Pow er 11.643 kW
Dd
F d 0.95 180 60
C
1080 300
180 60
2500
161.28
Take 160;
75 1.2
n no . o f belts required
11.643 1.14 0.95
7.137
Design of Flexible Elements 1.61
= n 8 belts
8 belts are required.
CA
A2 B
L D d
A
4 8
D d2
B
8
1173.8252
1080 3002
B
8
76050
New centre distance
C 1173.8252
1173.8252 2 76050
C 2314.796 mm
Given data:
N1
Speed radio i 3
N2
N1 1440
N 2 Speed of driven pulley, 480 rpm
3 3
D
But, i
d
3 200 600 mm
D d2
L D d 2C
2 4C
600 200 2
600 200 2 1500
2 4 1500
4283.30 mm
Designation
A V-belt cross-section C and of nominal inside Length
of 4394 mm shall be designated as C 4394 1S:2494
d N 1
60
200 1440
15.079 m/sec
60 1000
de eq uivalent pitch diameter
d p Fb
1.64 Design of Transmission Systems
200 mm
D 600
for 3; Fb 1.14
d 200
de 200 1.14
228 mm
P fa
No. of belts n
kW F c Fd
To Find F d:
CA
A2 B
L D d L N ominal P itch length
A
4 8 4450 mm
4450 600 200 D 600 mm
4 8
798.34 mm d 200 mm
2 2
D d 600 200
B
8 8
20,000 mm
798.34
798.34 2 20.000
1584.05 mm
Solution
Given data
P 50 kW 50 10 3 watts
we know
N1 1440
Speed ratio i 3
N2 480
dmin 200 mm
F b max 1.14
de max 300
dp max 263.15 mm
F b max 1.14
Design of Flexible Elements 1.67
N1
Dd
N2
1440
250 0.98
480
C
1.0
D
C 1 735
C min 0.55 D d T
556 mm
C max 2 D d
2 735 250
1970 mm
1
But C.S.A of belt W b T
2
14 tan 20
5.0955 mm
b W 2x
22 2 5.0955
11.808 mm
1
C.S.A of belt [ 22 11.808 ] 14
2
236.66 mm 2
D d2
L D d 2C
2 4C
738 250 2
725 250 2 735
2 4 735
3097 mm
Design power
142.7
kW 1.47 S 0.09 2.34 10 4 S 2 S
de
d N 1 0.250 1440
But S
60 60
18.85 m/s
and
Design power
0.09 142.7 4 2
[1.47 18.85 2.34 10 18.85 ] 18.85
285
10.26 kW
P Fa
No. of belts n
kW F c F d
1.70 Design of Transmission Systems
Dd
180 60
C
735 250
180 60 140.4
735
Fd 0.845 , from P.S.G Data book, Pg.No. 7.68
50 1.4
n number of belts
10.26 0.97 0.845
8.32
~
9 belts
CA
A2 B
L Dd
But A
4 8
3104 735 250
4 8
389.19
Design of Flexible Elements 1.71
C 389.19
389.19 2 29403.1
Solution
Given
N 1 1440 rpm, N 2 480 rpm
C1m
For the power of 7.5 kW, ‘B’ type belt may be selected.
For ‘B’ type belt dmin 125 mm , and dmax is calculated as
follows.
de max 175
(ie) dp max 153.5 mm
F b max 1.14
1.72 Design of Transmission Systems
Step 1
Let diameter of driving pulley d 140 mm
N1 1440
D d 140 0.98
N2 480
D 412 mm
D N1
i 3
d N2
Step 2
Pitch length of the belt
D d2
L 2C D d (from Pg.No. 7.61)
2 4C
412 1402
2 1000 412 140
2 4 1000
2885.4 mm
Design of Flexible Elements 1.73
Step 3
Calculation of Design power
50.8
kW 0.79S 0.09 1.32 10 4 S2 S
de
d N1
S
60
0.140 1440
10.555 m /sec
60
140 1.14
159.6 mm
~
160 mm
0.09 50.8 4 2
kW 0.79 10.555 1.32 10 10.55 10.55
160
0.3068 10.555
3.2368 kW
1.74 Design of Transmission Systems
Step 4
To find the No. of belts
P Fa
number of belts n
kW F c F d
P 75 kW ,
kW 3.2368 kW
Dd
Arc of contact angle 2 cos 1
2c
Dd
180 60
c
412 140
180 60
1000
163.68 ~
163
75 1.1
25.285 ~
26 belts
3.2368 1.05 0.96
CA A2 B
where
L
A D d
4 8
2885.4
412 140
4 8
504.58
D d2
B 9,248
8
C 504.58
504.58 2 9248
C 999.91 mm
1
Take 1% of L 2888 28 mm
100
1027 mm
1.76 Design of Transmission Systems
width of pulley n 1 e 2f
500 mm
Specifications
Type of Belt: B 2845/116 IS 2494 (V Belt)
Number of Belts: 26
Pitch diameter of smaller pulley: 140 mm
Pitch diameter of bigger pulley: 412 mm
Centre distance: 1027 mm
Problem 1.16 A motor driven blower is to run at 600 rpm
driven by an electric motor of 8.5 kW at 1900 rpm. Design v-belts.
Given data
Power P 8.5 kW
Solution
Step 1: Selection of cross section of belt
Since the diameters of the pulleys are not given, they
can be assumed.
From PSG Data book, Pg.No. 7.58
for the power 8.5 kW, ‘C ’ type belt may be selected.
For ‘C ’ type belt, dmin 200 mm
Design of Flexible Elements 1.77
(or)
de dpmax F b max
max
F b max 1.14
de
max 300
dpmax 263.15 mm
F b max 1.14
and
and
0.98 (assumed)
1900
D 230 0.98
600
713.76 mm
D 713.76
i 3.1
d 230
C
0.95
D
C 0.95 713.76
C 678.072 mm
C min 0.55 D d
533.06 mm
C max 2 D d
2 713.76 230
1887.52 mm
Design of Flexible Elements 1.79
D d2
L 2C D d
2 4C
713.76 230 2
2 678.072 713.76 230
2 4 678.072
2819.35 mm
142.7
kW 1.47 S 0.09 2.34 10 4 S2 S
de
N1
since S belt speed
60
0.230 1900
60
22.8 m/s
de dp Fb (or) d F b
230 1.14
de 262.2 de 300
max
0.09 142.7 4 2
kW 1.47 22.8 2.34 10 22.8 22.8
262.2
kW power 10.113 kW
P Fa
Number of belts
kW Fc F d
F a 1.3
F c 0.95
Dd
Arc of contact 180 60
C
713.76 230
180
678.072
60
137
Design of Flexible Elements 1.81
F d 0.85
8.5 1.3
Number of belts n
10.113 0.95 0.85
1.353 ~
2 belts
CA
A2 B
where
L D d
A
A 8
354.6 mm
D d2
B
8
713.76 2302
8
29252.96 mm2
Given Data
P 0.75 kW; N1 780 rpm; N 2 120 rpm
Solution
Step 1: Selection of cross-section of belt
Since the diameters of pulleys are not given they can
be assumed.
(or)
de 125 mm
max
D
and corresponding to ratio,
d
Design of Flexible Elements 1.83
F b max 1.14
de
max 125
dp max 109.64 mm
Fb max 1.14
d = 100 mm
N1
Diameter of larger pulley D d
N2
where
and
780
D 100 0.98
120
637 mm
D 637
i 6.37
d 100
C
0.85
D
C 0.85 637
C 541.45 mm
C min 0.55 D d t
413.35 mm
C max 2 D d
2 637 100
1474 mm
D d2
L 2C D d
2 4C
637 1002
2 541.45 637 100
2 4 541.45
2373.72 mm
19.62
kw 0.45 S 0.09 0.765 10 4 S 2 S
de
d N1
Since S belt speed
60
0.100 780
60
4.084 m/s
de dp Fb
100 1.14
0.09 19.62 4 2
kw 0.45 4.084 0.765 10 4.084 4.084
114
0.911 kW
P Fa
Number of belts
kw F c F d
F a 1.1
1.86 Design of Transmission Systems
F c 1.1
Dd
Arc of contact 180 60
C
637 100
180 60
541.45
120.49
F d 0.83
0.75 1.1
Number of belts n
0.911 1.1 0.83
0.9918 ~
1 belt
Centre distance ‘C ’ A
A2 B
L D d
where A
4 8
386.33 mm
Design of Flexible Elements 1.87
D d2
and B
8
637 100 2
8
36046.12 mm 2
Given data
P 80 kW; N 1 720 rp m; N2 300 rpm ; D 1500 mm ;
Solution
Step 1: Selection of cross-section of belt
From PSG Data book, Pg.No. 7.58, for the power 80
kW, “D” type belt may be selected.
N1
Diameter of larger pulley D d
N2
N2 1
dD
N1
300 1
1500
720 0.98
637.75 mm
D d2
L 2C D d
2 4C
1500 637.752
2 1650 1500 637.75
2 4 1650
L 6770.6 mm
506.7
kw 3.22 S 0.09 4.78 10 4 S 2 S
de
dN 1
Since S belt speed
60
0.6377 720
60
24.04 m/s
de dp Fb
637.75 1.13
720.657 mm
. . D
[ . F b 1.13 corresponding to ratio from PSG Data
d
book Pg.No. 7.62]
0.09 506.7 4 2
kw 3.22 24.04 4.78 10 [24.04 ] 24.04
720.657
34.6 kW
P Fa
Number of belts n
kW F c F d
Power P 80 kW (given)
1.90 Design of Transmission Systems
F c 1.1
Dd
Arc of contact 180 60
C
1500 637.75
180 60
1650
148.64
F d 0.82
80 1.5
Number of belts =
34.6 1.1 0.82
belts 3.84 ~
4
L D d
where A
A 8
882.2 mm
D d 2
and B
8
Design of Flexible Elements 1.91
1500 637.5 2
8
92934.3 mm 2
C 882
882 2 92934.3
1709.6 mm
dw
d
S tran d
C o re
Fig. 1.11(a) 6x7 w ire rop e
R o pe
R1 R1
Fig. 11.11(b) 2
C ross-sectio n o f a rop e.
Design of Flexible Elements 1.93
(ii) 6 19 ropes
(iii) 6 37 ropes
(iv) 8 19 ropes
(d) Usage
(i) Running ropes
W Wr
d
A ... (1)
Where W weight of the load to be lifted
Design of Flexible Elements 1.95
dw
b Er
D ... (2)
Where, E r Young’s modulus of the entire rope
0.8 10 5 N mm 2 or
3
Er E
8
dw wire diameter
D s heave diameter
W Wr a
a
g A ... (3)
V2 V1
t
1.96 Design of Transmission Systems
W Wr 2as h E r
s
A
1
1
d l g
... (5)
where, h slack during starting
ne d b
ae d b a
T 2
A 0.4 d
4
dw
Er A
D
Design of Flexible Elements 1.99
W Wr
Wa a
g
v2 v1
where a
2
starting load W st 2 W d
2 W W r
Wen W d W b
Wse W b W s
Wae W d W b Wa
W d W1 W 2
30 15 45 kN 45 103 N
180 10 3
2
1800 N mm2
10
Design of Flexible Elements 1.101
270 kN
d d
dW 0.0624 d
1.5 i
1.5
6 19
Er dW
Bending load on the rope W b A
D
80 10 3 0.0624 d
0.4d 2
30 d
66.56 d2 N
Wd
Load on the rope due to acceleration W a a
g
45 10 3
1
9.81
4587.15 N
u 1800
A 0.4 d2
FOS 6
49,587
d2
53.44
d 30.46 mm
Solution
Given data:
2. Factor of safety
n n duty facto r Refer PSG Data book Pg. No.9.1
Design of Flexible Elements 1.103
n 10 1.6 16
d ep th 350 m
w 22295 N
d 41
dw dia of wire 2.56 mm
1.5 i
1.5
6 19
D
Min 100
d
E r dW 0.8 10 5 2.56
Bending stress
D 4100
b 49.95 N mm 2
A 0.4 d2
4
0.4 41 2
4
528.1 mm 2
V 600
a
60t 60 20
0.5 m sec 2
Ww
Additional load due to acceleration W a a
g
55 10 3 22295
0.5
9.81
3939.6 N
880 10 3
8.177 16 Design factor of safety
107.6126 10 3
55 10 3 22295 26.378 10 3
103.673 10 3 N
880 10 3
8.488 16
103.673 10 3
Solution
Given
W 2 weight of bucket = 2 kN
W d W1 W 2
W d 10 kN 2 kN 12 kN 12 10 3 N
Time = 3 seconds
i 6 37 type
P d 3 6 12
P d 3 72 kN
P d 216 10 3 N
Design load
2. Area of rope A
Ultima te stress
216 10 3 N
1700 N/mm 2
A 127 mm 2
A 0.4 d2
Design of Flexible Elements 1.107
A
d
0.4
0.4
127
17.8 mm
d
dia of wire d w
1.5 i
18
1.5
6 37
0.8053 mm
3. Diameter of sheave
D
100
d
D 100 d 100 18
1800 mm
Er dw 0.8 10 5 0.8053
Bending stress
D 1800
1.108 Design of Transmission Systems
b 35.79 N/mm2
wb b A
w.k.t
A 0.4 d2
4
0.4 182
4
101.78 mm 2
w b 35.79 101.78 N
3642.7 N
3.6427 kN
0.66 m/s 2
load due to acceleration w a
Ww
wa a
g
10 10 3 63.7
0.66
9.81
w a 677.06 N
Design of Flexible Elements 1.109
14382.7 N
14.3827 10 3 N
216 10 3 N
14.3827 10 3 N
10 10 3 63.7 3.642 10 3
13.7057 10 3 N
216 10 3 N
13.7057 10 3 N
Solution
Given
W 1 Weight of the load to be lifted 18 kN
W1 W2
18 10 28 kN 28 10 3 N
a 1 m /s 2; F.O.S 6; as 0.38 d2
a acceleration
6 28
168 kN
Design of Flexible Elements 1.111
d d
dW 0.0624 d
i 1.5
1.5
6 19
80 10 3 0.0624 d
Wb 0.38 d 2
30 d
63.232 d2 N
2854.23 N
Wd Wb Wa
u 1800
as 0.38 d 2
FOS 6
30,854.23 50.729 d2
d 24.66 mm
Solution
Given that
i 6 19 wire rope
d 15 mm
D 400 mm
p
w.k.t 0.0012
v
P 0.0012 v
P 0.0012 1120
P 1.344 N /mm 2
Design of Flexible Elements 1.113
2Wmax
Also w.k.t P
dD
P d D 1.344 15 400
W max
2 2
dw
b Er
D
Sheave materials
Cast iron sheaves are employed in light and medium
service where as steel castings are often employed for heavy
service.
Solution
Given data
Wire Type 6 19 wire rope
v 200 m/min
W elevator 10 kN
W passenger 9 kN
FOS = 10
10 kN 9 kN
19 kN
19 10 190 kN
D min/d 27
850 mm
(xi) r4 15 mm;
Design of Flexible Elements 1.117
ADDITIONAL PROBLEMS
APRIL 1998:
Design a belt drive to transmit 22.5 kW at 740 rpm
to an aluminium-rolling machine. The speed ratio being 3.0
and the distance between the pulleys is 3 meter. Diameter
of the rolling machine pulleys is 1.2 meter. Take fabric belt
and cast iron pulley. Assume Co-efficient of friction
0.2, Permissible tension for 8 ply fabric belt = 12.5
kg/cm width. Take the length of the belt, 1% less to give
initial tension.
APRIL 2002:
Design a fabric belt to transmit 10 kW at 450 rpm
from an engine to a line shaft at 1200 rpm. The diameter
of the engine pulley is 600 mm and the distance of the
shaft from the engine is 2 meter.
OCTOBER 1996:
Design a chain drive to transmit 5 kW at 900 rpm
of sprocket pinion. The speed reduction is to be 2.5:1. The
driving motor is mounted on an adjustable base. Assume
that the load is steady, the drive is horizontal and the
service is 16 hours per day.
OCTOBER 2000:
Select a suitable deep groove ball bearing for a
drilling machine spindle of 40 mm diameter and suggest
necessary tolerances on the shaft and housing. Radial load
is 2.0 kN. Thrust is 1.5 kN. Spindle speed is 3000 rpm.
Desired life is 3000 hours.
1.118 Design of Transmission Systems
D rive n S procket
C e ntre D istan ce
1.4.2 Advantages:
1. Chain drives can be used for long or short center
distances.
2. From a single driving sprocket, a number of
shafts can be driven in the same or opposite
direction by means of a chain.
3. Chain drives are more compact.
4. The efficiency of chain drives is approximately
98% (higher than belt drives).
Design of Flexible Elements 1.119
1.4.3 Disadvantages
1. Periodic maintenance is required, particularly
lubrication and slack adjustment.
2. Noisy operation, when compared to belt drives.
3. Design is more complicated (sprocket design).
4. Chain drive is unsuitable where precise motions
is required due to polygonal effect and wear in
the joints.
1.4.4 Applications:
1. Transportation industry (Bicycles, motor cycles
and automobile vehicles, etc.)
2. Textile industry.
3. Building construction and material handling.
Db Dr
DP
A1 A2
W A3
B ush C hain R oller
C hain Sim p lex C h ain D up lex C hain Triplex C hain
Fig.1.15
1.120 Design of Transmission Systems
1. Chain
A Dp b
2. Sprockets
A sprocket is a profiled wheel with teeth that mesh
with a chain. The name sprockets applies generally to any
wheel upon which are radial projections that engage a
chain passing over it.
The operating capacity of a chain drive depends upon
the quality of the sprockets. Generally sprockets are made
up of cast iron or hardened steel. Sprocket with small
radius is termed as pinion-sprocket and with large radius
is called wheel sprocket.
p
d Pitch circle diameter of sprocket
sin /Z
p
sin 180/ Z
Pitch Circle
D riving Diam eter
C learance for
Belt U nderside
Fig.1.16 S procket
1.122 Design of Transmission Systems
Dr
o
1 80
2 = Z
r
2
2
d
o
3 60 2
=
Z
p
d = Pitch C ircle D ia m eter of Sp rocket =
sin ( /2)
p
o
sin (1 80 /z)
Fig.1.17. Action of C hain E ngaging Spro cket Teeth.
Step 2
Z2
Since i
Z1
Z 2 iZ 1
Z min 7 teeth
Step 3
a
i.e., pmax
30
1.124 Design of Transmission Systems
a
pmin
50
Select the standard pitch from databook 7.71, 7.72 & 7.73
Step 4
Simplex - R
Duplex - DR
Triplex - TR
Step 5
Refer PSG databook, Page No. 7.77.
Qv
N in kw
102 n K s
ZpN
m /sec.
60 1000
p pitch in m m
k1 k2 k3 k4 k5 k6
1.126 Design of Transmission Systems
(by assuming K1 K2 K3 K4 K5 K6 1
Qv
N Calculate Q
102 n K s
If Q [Q] then change the chain no. and read the
values of A, W and [Q] and check again Q breaking load.
Step 6
Q
[n]
P
P P t P c Ps
102 N
Pt kg f
V
Design of Flexible Elements 1.127
P t C entrifugal tension
W v2
Pc kg f
g
N P ower in kW given
g 9.81 m/sec 2
Ps K W a K Coefficient of sag
(refer PSG Data book page No.
7.78)
value of K depends on position of
chain drive
W Weight/m length of chain kgf
a Centre distance in meter
To Find ‘a’: Centre distance
2
Z2 Z1
Z1 Z2 2
lp 2ap (no. of links)
2 ap
ao
where ap
p
p Pitc h
Ps K W a
K Coefficient. of sag
W Weight/m length
Calculate P and
Q
[n]
P
Design of Flexible Elements 1.129
[n] n
Step 7
1. Pitch
2. Chain velocity
A bearing Area cm 2
K s service factor
[]
Step 8
Diameters of pinion and wheel d and D
p
d
180 d dia. of smaller sprocket
sin
Z1
p
D
180 D dia. of larger sprocket
sin
Z2
R Rc
R R Rc
Design of Flexible Elements 1.131
R R cos
2
R 1 cos
2
360
z
Solution
Given Data:
Z2 N1
Tra ns mission ratio
Z1 N2
N1 900
i Transmission ratio 3
N2 300
Step 2: From PSG Design data book, refer Page No. 7.74.
1.132 Design of Transmission Systems
For i 2 to 3 ; Z 1 25 to 27
i 3 to 4 ; Z 1 23 to 25
Z 2 i Z1 3 27 81
550
pitchmax pmax 18.33 mm
30
550
pitchmin pmin 11 mm
50
Select roller chain from PSG Data book Page No. 7.72
Pitch p 15.875 mm
Qv
N kW
102n Ks
N given power
N 15 kW
Z1 p N1 27 15.875 900
v
60 1000 60 1000
6.429 m/sec
Ks 1
Q 6.429
15
102 11 1
1.134 Design of Transmission Systems
15 102 11 1
Q 2617.825 kgf
6.429
Step 6
ao
where ap
p
550
34.64
15.875
34.64
550 mm
p pitch 15.875 mm
2
Z2 Z1
m
2
Read the value of ‘m’ directly from PSG data book
Pg.No. 7.63 Z 2 Z 1 82 27 55;
e
e2 8m
a p
4
71.5
71.5 2 8 76.6
a 15.875
4
a 549.98
a 550 mm
1.136 Design of Transmission Systems
P P t Ps Pc
102 N
P t Tangential force due to power Transmission
v
102 15
Pt N 15 kW
6.429
237.98 kg f v 6.429 m/sec
W v2
P c Centrifugal fus ion
g
1.78 6.429 2
9.81
7.499 kg f
W 1.78 kg f
550
6 1.78
1000
5.874 kg
K Coefficient of Sag from PSG data book 7.78
6 (Horizontal)
a 550 mm 0.55 m
P 237.98 7.499 5.874
251.353 kgf
Design of Flexible Elements 1.137
Q 4440
[n]
P 251.353
17.66 11
Av
N kW
102 Ks
[] Ks 1
2.24 kg f/mm 2
p
Step 9: Pitch dia. of small sprocket d
180
sin
Z1
15.875
180
sin
27
136.74 mm
p
Pitch dia. of large sprocket D
180
sin
Z2
15.875
180
sin
82
414.46 mm
Given Data:
Power 10 kW 10 10 3 W atts:
Z2 N1
Transmission ratio i
Z1 N2
1440
i 2.4
600
Design of Flexible Elements 1.139
Take Z 1 27 teeth
Z 2 2.4 27 64.8
Take Z 2 66 teeth
where p pitch
750
Pitchmax P max 25 mm
30
750
Pitchmax P min 15 mm
50
p pitch 19.05 mm
Q.V
N kW
102. n ks
p Z 1 N1
N 10 kW; V
60 1000
19.05 27 1440
12.34 m sec
60 1000
Select n 13.2
K1 K2 K3 K4 K5 K6 1
KS 1
Q 12.34
10
102 13.2 1
102 13.2 1 10
Q 1091.08 kgf
12.34
Step 6
(a) Calculation of Length of chain, and
66 27 38.5
lp 2 39.37
2 39.37
126.217 m
ao
Where ap
p
750
ap 39.37
19.05
e
e2 8m
(b) Finalc entredistanc e a p
4
767.18 mm
Z1 Z2
e lp
2
66 27
128 81.5
2
1.142 Design of Transmission Systems
P P t P S P C
102 N
V
102 15
123.98 kg f
12.34
W v2
P C Centrifugal tension
g
1.47 12.342
9.81
22.818 kg f
153.5894 kgf
K 6 (Horizontal)
Design of Flexible Elements 1.143
Q 3200
Actual factor of safety [n]
P 153.5894
1.05 12.34
10 N 10 kW
102 1
78.7219 kg f cm 2 A 1.05 cm 2
or v 12.34 m sec
2 KS 1
0.78721 9 kgf mm
Solution
Given data
N 8.5 kW
N 1 900 rpm
N 2 380 rpm
ao 550 mm
Step 1
Calculation of transmission ratio (i)
Z2 N1
Transmission ratio i
Z1 N2
900
i
380
2.368
Step 2
From PSG Data book Pg No. 7.74
For i 2 to 3
Z 1 no o f teeth o n pinio n = 25 to 27
Take Z 1 27 teeth
Z2 Z1 i
27 2.368
64.4
Take Z 2 66 teeth
Design of Flexible Elements 1.145
Step 3
From PSG design data book Pg.No. 7.74
where p pitch
a 550
P max 18.33
30 30
a 550
P min 11
50 50
Step 4
Selection of chain
Step 5
Calculate power transmitted based on breaking load.
1.146 Design of Transmission Systems
Q.v
N kW
102. n.K s
Z1 p N1
v
60 1000
27 15.875 900
60 1000
6.4293 m/sec
K s 1 (Assume)
. .
. since the specific condition is not given in
problem.
K s K 1 K 2 K3 K 4 K5 K 6 1
Q 6.4293
8.5
102 11 1
8.5 102 11 1
Q
6.4293
Q 1483.36 kg f
Step 6
(a) Calculation of length of chain
ao 550
where ap
p 15.875
34.64
m 34.7
2
Z2 Z1
w.k.t m 34.7
2
64 27 34.7
Lp 2 34.62
2 34.64
115.74 links
Length of chain l lp p
l 116 15.875
1.148 Design of Transmission Systems
l 1841.5 mm
Take, l 1842 mm
e
e2 8m
(b) Final centre distance a p
4
Z1 Z 2
w here e lp
2
64 27
116
2
70.5
70.5
70.52 8 34.7
a 15.875
4
a 551.66 mm
Take a 552 mm
Step 7
Check actual factor of safety
Q
Actual factor of safety n
P
P Pt Ps Pc
102 N
v
Design of Flexible Elements 1.149
102 8.5
Pt
6.4293
P t 134.851
N 8.5 kW
v 6.4293 m/sec
W v2
P c Centrifugal function
g
1.78 6.42932
9.81
7.5 kg f
P Pt Pc Ps
148.225 kg f
Q
[n]
P
4440
148.225
29.95 1 allowable FOS
The design is satisfactory.
1.150 Design of Transmission Systems
Step 8
Checking of Allowable Bearing stress
From PSG Data Book P.No. 7.77
The allowable stress for pitch of 15.875 and speed <
1000 rpm.
2.42 kg f/mm 2
1.4 6.4293
8.5
102 1
8.5 102 1
1.4 6.4293
96.322 kg f/cm 2
0.9632 kg f/mm 2
Step 9
p
Pitch dia of small sprocket d
180
sin
Z1
15.875
d
180
sin
27
136.74 mm
Design of Flexible Elements 1.151
p
Pitch dia of large sprocket D
180
sin
Z2
15.875
D
180
sin
64
D 323.53 mm
Solution
Power transmission N 15 kW
Service 15 hours/day
500
pmax 16.66
30
500
pmin 10
50
a 500
(ie) p 14.3 mm
35 35
1.152 Design of Transmission Systems
N1 1000
Transmission Ratio, i 2.857
N2 350
Z 1 25 (assumed)
Z 2 i Z 1 2.85 25 71.42 ~
72
Q .v
PN kW
102n Ks
N Power to b e transmitted 11 kW
n F.O.S to be assumed
k s Service facto r
Service factor ks k1 k2 k3 k4 k5 k6
k 3 1.0 a p 30 to 50 p
1.875
n 11 1.875
20.625
Z1 N1 p 25 1000 15.875
Chain velocity, v
60 1000 60 1000
6.61 m/s
N n K s 15 20.625 1.875
Q
v 6.61
87.75 kg f
1.154 Design of Transmission Systems
Now the chain is checked for its actual F.O.S and for
allowable stresses.
Q
Checking for actual F.O.S, [n ]
P
where P P t P c P s
P s 4 17.8 0.5
35.6 kg f
346.337
Q 4440
Hence [n ] 12.81 11
P 346.337
N Ks
AV
A Bearing area
15 1.875
Hence
1.4 6.61
But
ao 500
ap 31.5
p 15.875
Hence
25 72 56
lp 2 31.5
2 31.5
e
e2 8 m
a from P.S.G. Data book, Pg. No.
4
7.75
Z1 Z 2
But e lp
2
Design of Flexible Elements 1.157
25 72
114
2 65.5
From P.S.G. Data book, Pg.No. 7.76, m 54 , for
Z 2 Z 1 48
65.5
65.5 2 8 54
Hence a 15.875
4
506.47 mm
0.5 F
But F 0.02 a
501.48 mm
P 15.875
d 126 127 mm
180 180
sin sin 25
Z
1
pitch diameter of wheel sprocket D
P 15.875
D 363.9 364 mm
180 180
sin sin 72
Z
2
Specifications
Type of chain: 10 A 2 DR 50 Ro ller c hain
Solution
Given Data
Power of motor N 15 kW
Speed o f mo to r N 1 1250 rpm
Step 1
Calculation of transmission ratio
Z2 N1
Transmission ratio
Z1 N2
N1 1250
i Transmission ratio 2.27
N2 550
Step 2
From P.S.G. Data Book, Pg.No. 7.74
For i 2 to 3; Z 1 25 to 27
Z 2 i Z 1 2.27 27 62
Step 3
From P.S.G. data book, Pg.No. 7.74
Optimum centre distance a (30 to 50) P
where a approximate centre distance
p pitch of chain
a 700
pitchmax b max 23.33 mm
30 30
a 700
pitchmin b min 14 mm
50 50
Step 4
Selection of chain number
Select roller chain from P.S.G. Data book, Pg.No.
7.72
The available chain Number are 10 A and 10 B
Select 10 A - 2 Duplex chain
Pitch p 15.875 mm
Corresponding to chain number selected, take the
values of
Step 5
Calculate power transmitted based on breaking load
From P.S.G. Data book, Pg.No. 7.77
Qv
N kW
102 n k s
K5 K 1 K2 K3 K 4 K 5 K 6 1
Q 8.929
15
102 13.2 1
ao
where ap
p
p is pitch in mm
700
ap 44.09
15.875
2
62.27
62 27 2
lp 2 44.09
2 44.09
133.38
Length of chain l lp p
133.38 15.875
2117.46 mm
2117.5 mm
1.162 Design of Transmission Systems
e
e2 8 m
a p
4
Z1 Z2
But e lp
2
27 62
133.38 88.88 mm
2
88.88
88.88 2 8 31
a 15.875
4
699.90
a~
700 mm
Step 7
Check the actual factor of safety
Q
Actual factor of safety [n]
P
where
P Pt P s P c
102 N
v
Design of Flexible Elements 1.163
102 15
8.929
171.35 kg f
W v2
P c Centrifugal tension
g
1.78 8.929 2
Pc 14.46 kg f
9.81
k.W.a
and
700
P s 6 1.78
1000
7.476 kg f
193.286 kg f
1.164 Design of Transmission Systems
Q 4440
[n] 22.97 13.2
P 193.286
Step 8
Checking of Allowable Bearing stress. From P.S.G.
data book, Pg.No. 7.77, corresponding to speed of rotation
of sprocket 1600 rpm , and pitch 15.875.
Av
N
102 Ks
1.4 8.929
15 122.39 kg f/cm 2
102 1
Or
1.22 kg f/mm2
[]
1.85 kg f/mm2
Step 9
Pitch dia of small sprocket
p
d
180
sin
Z1
15.875
d 136.74 mm
180
sin
27
p
D
180
sin
Z2
15.875
180
sin
62
D 313.43 mm
Solution
Power transmitted N 11 kW
Service 16 hours/day
a 500 a 500
(ie) pmax 23.33 mm; pmin 10 mm
30 30 50 50
N1 970
Transmission ratio, i 2.93
N2 330
Z 1 25
Z 2 iZ 1 2.93 25 73
Q .v
N kW
102n Ks
N P ower to be transmitted 11 kW
n F.O.S to be assumed
K s Service factor
Service factor ks k1 k2 k3 k4 k5 k6
k 3 1.0 a p 30 to 50 p
1.875
k s 1 and Z 1 25
(or)
20.625
1.168 Design of Transmission Systems
Z1 N1 p 25 970 15.875
Chain velocity, v
60 1000 60 1000
6.41 m/s
N n Ks
Q
v
11 20.625 1.875
6.41
66.36 kg f
Now the chain is checked for its actual F.O.S and for
allowable stresses.
Q
Actual F.O.S, [n ]
P
where P P t P c P s
102 N 102 11
Pt
v 6.41
Design of Flexible Elements 1.169
175.03 kgf
W v2
g
17.8 6.412
9.81
74.55 kgf
hence k 4
a 0.5 m given
W 17.8
P s 4 17.8 0.5
35.6 N
285.18
1.170 Design of Transmission Systems
Q 4440
Hence [n ] 15.56
P 288.18
ie 15.56 11
N ks
Av
A Bearing area
2
Z2 Z1
Z 1 Z 2
2
lp 2ap
2 ap
from P.S.G. Data book Pg.No. 7.75
Design of Flexible Elements 1.171
But
a0 500
ap 31.5 from P.S.G. Data book Pg.No. 7.7 5
p 15.875
Hence
2
73 25
25 73 2
lp 2 31.5
2 31.5
112.24
112 15.875
1778 mm
e
e2 8 m
a p (from P.S.G. Data book,
4
Pg.No.7.75)
Z1 Z2
But e lp
2
25 73
112 63
2
m 58.4 , for Z 2 Z1 73 25 48 from P.S.G. Data
book, Pg.No. 7.76
1.172 Design of Transmission Systems
Hence
63 8 58.4
2
a 63 15.875
4
484.8 mm
0.5 F
But F 0.02 a
4.848 mm
479.95 mm
p
d
180
sin
Z1
15.875
127 mm
180
sin
25
p 15.875
D 369 mm
180 180
sin sin
Z2 73
Specifications
Type of chain: 10 A-2 DR 50 Rolon chain
Solution
Given data
Power N 8 kW
Step 1
Calculate of transmission ratio i
Z2 N1 1500
i 2.5
Z2 N2 600
1.174 Design of Transmission Systems
Step 2
From P.S.G data book, Pg.No. 7.74
for i 2 to 3, Z 1 No. of teeth on pinion 25 to 27
Take Z 1 27 teeth
Z 2 2.5 27 68 teeth
Step 3
Fro m P.S.G Data bo o k, Pg.No. 7.74
where p pitch
800
Pitchmax pmax 26.66
30
800
Pitchmin pmin 16
50
p 19.05 mm
Step 4
Selection of chain No.
Select roller chain from P.S.G Data book, Pg.No. 7.72
from the available chain No.
Select chain No. 12A - 1 (simpler roller chain)
p pitch 19.05 mm
Design of Flexible Elements 1.175
Step 5
From P.S.G Data book, Pg.No. 7.77, power
transmitted on breaking load
Qv
N
102 N 1 k s
N 8 kW
p Z1 N1 19.05 27 1500
V
60 1000 60 1000
19.05 27 1500
12.85 m/s
60 1000
K 1 K2 K 3 K 4 K 5 K 6 1
KS K1 K 2 K3 K 4 K5 K 6 1
Q 12.85
8
102 13.2 1
Step 6
From P.S.G Data book, Pg.No. 7.75 length of
continuous chain in multiples of pitches
2
Z2 Z1
Z1 Z2
2
lp 2 a p
2 ap
ao
where ap
p
a o initially assu me d centre distance in mm
800 mm
800
ap 41.99
19.05
2
68 27
27 68 2
lp 2 41.99
2 41.99
131.48 mm
132 mm
Length of chain l lp p
132 19.05
2514.6 mm
m 42.6
e
e2 8 m
final centre distance ‘a’ p
4
Z1 Z 2
but e lp
2
27 68
132 84.5
2
84.5 84.52 8 42.6
a 19.05
4
803.9 mm
804 mm
Step 7
Check the actual factor of safety from P.S.G Data
book, Pg.No. 7.78
Q
Actual factor of safety [n]
P
Q breaking load of the cha in 3200 kg f
P Pt P s P c
where
P t tangential force due to pow er transmission
102 N 102 8
63.5 kg f
v 12.85
W v2
P c centrifugal tension
g
1.47 12.85 2
9.81
24.74 kg f
1.178 Design of Transmission Systems
a 796 mm 0.796 m
P s 6 1.47 0.796
7.02 kg f
95.26 kg f
Q
Actual factor of safety [n]
P
3200
95.26
Step 8
Checking of Allowable bearing stress from P.S.G Data
book, Pg.No. 7.77
or
Solution
Given
P 10 kW ; N1 1000 rp m, N 2 350 rp m ,
a 500
(ie) pmax 16.36 mm
30 30
500
pmin 11
50
N1 1000
Transmission ratio i 2.857
N2 350
1.180 Design of Transmission Systems
Z 1 25 As su med
Z 2 iZ 1
2.857 25
71.425
~
72
N ks n
Q
v
ks k1 k2 k3 k4 k5 k6
k s 1.5 1 1 1 1 1.25
1.875
n 11 for ks 1 and Z 1 25
n 11 1.875
20.625
Z 1N 1p
Chain velocity, V
60 1000
25 1000 15.875
60 1000
6.614 m/s
58,469.72 N
Q
Actual factor of safety, [n]
P
where P P t P c P s
Now
N
Newtons
v
10000
1575 Newton
6.35
Wv 2
g
30.2 6.352
Pc
9.81
124.132 N
kWa
P s 4 30.2 0.5
60.4 N
1759.53 N
Q
Hence [K n]
P
66600
37.85
1759.53
The induc ed bearing stress o ver the pro jec ted area o f
the c hain is given by
N ks
Av
10,000 1.875
210 6.35
14.06 N/mm 2
a0 500
But ap 31.5
p 15.875
Hence,
2
72 25
25 72
2
L p 2 31.5
2 31.5
113.2
l lp p
Design of Flexible Elements 1.185
114 15.875
l 1810 mm
e
e2 8m
a p
4
where
Z1 Z2
e lp
2
25 72
114
2
65.5 ~
66
Corresponding to Z 2 Z1 72 25 47
m 56
Hence
66
662 8
56
a 15.875
4
510 mm
But F 0.02 a
1.186 Design of Transmission Systems
0.5F
0.5 0.02 a
5.1 mm
510 51
505 mm
p 15.875
d
180 180
sin sin
Z1 25
d 127 mm
and
p 15.875
D
180 180
sin sin
Z2 72
D 364 mm
Specifications
Type of chain 10 A 2 DR 50 Rolon chain
Given data
Power of motor N 10 kW
Solution
Step 1: Calculation of transmission ratio
From PSG Data book, Pg.No: 7.74
Z2 N1
Transmission ratio i
Z1 N2
N1 960
i 2.74
N2 350
For i 2 to 3; Z 1 25 to 27
i 3 to 4; Z 1 23 to 25
Z 2 i Z 1 2.74 27
Z 2 73.98 ~
74
Z 2 74 teeth
500
Pitchmax 16.66
30
500
Pitchmin 10
50
Q.v
N
102n K s
Z1 p N1 27 15.875 960
We know that v
60 1000 60 1000
v 6.858 m/s
Ks 1
102n k s N 102 11 1 10
Q
u 6.858
Step 6
(a) calculation of length of chain
(b) final centre distance
1.190 Design of Transmission Systems
2
Z2 Z1
Z1 Z2 2
2ap
2 ap
ao
where ap
p
500
ap
15.875
ap 31.49
2
74 27
27 74 2
lp 2 31.49
2 31.49
Take l 1840 mm
e e2 8 m
a p
4
z1 z2 27 74
where e lp 116
2 2
e 65.5 mm
2 2
z2 z1 74 27
and m
2 2
m 55.95
65.5
65.52 8 55.95
15.875 505.97
4
a~
506 mm
Step 7
Check the actual factor of safety
From PSG Data book, Pg.No. 7.78
Q
Actual factor of safety [n]
P
and P Pt P s P c
102 10
Pt
6.858
148.73 kg f
k6
506
P c 6 1.78 5.404 kgf
1000
P 148.73 8.533 5.404 162.66 kg f
Q 4440
[n] 27.29 11
P 162.66
Step 8
Checking of Allowable bearing stress
From PSG Data book, Pg.No. 7.77, corresponding to
pitch = 15.875 mm, speed less than 1000 rpm
Design of Flexible Elements 1.193
102N k s 102 10 1
AV 1.4 6.858
[]
Step 9
Pitch diameter of small sprocket d
p 15.875
d
180 180
sin sin
Z1 27
d 136.74 mm
Pitch diameter of large sprocket D
p 15.875
D
180 180
sin sin
Z2 74
D 374 mm
Chapter 2
2.1 INTRODUCTION
Gears are defined as toothed wheels, that transmit
power and motion from one shaft to another due to the
successive engagement of teeth.
2.1.2 Disadvantages
1. Gear drives are costly.
2. Maintenance cost is high.
3. Manufacturing processes for gears are
complicated.
4. Gear drives require careful attention.
5. Accurate alignment of shafts is required.
Too th spa ce
d
Pc
Z
Pc Pd
Forms of Teeth
1. Involute teeth
2. Cycloidal teeth.
An Involute of a circle is a plane curve generated
by a point on a tangent, which rolls on the circle
2.8 Design of Transmission Systems
V c1 on
o m m al
C rm
No
O1 1 V c2
M
2
O2
without slipping.
(Normal at any point of an involute is a tangent
to the circle).
A cycloid is the curve traced by a point on the
circumference of a circle which rolls without
slipping on a fixed straight line.
2.5.4 Disadvantages
Manufacturing of cycloidal gear is difficult.
Z 1 =3 6 To oth G ea r
1 (Pinion )
d
N1 Z2 d2
i
N2 Z1 d1
2
Z min
sin 2
Mt 2 Mt
Tangential Force, Ft
d/2 d
(Or)
Ft
F
cos
O1
p in ion
d river
Pre ssure
line F
Pitch po int
G ear
d riven
Power transmitted
P F t v Pinion
d river
v pitch line velocity O1
dN Ft Pitch
v ; p oin t
60 F
Fr
2. Radial component of
Fr
force F r F
Pitch
Radial component of Ft p oin t
force F r, is a separating
G ea r
force, since it is always d riven
directed towards the center
of gear, tries to separate the O2
60 P
Torque Transmitted M t
2 N
2.14 Design of Transmission Systems
We know
t
Bending Moment, M b F t h...(1) N
Se ctio n b
bt 3 t at XX
I and y 1 Fig:2.11 A
12 2
6F t h
b Permissible bending stress (N / mm2)
bt 2
bt 2
b
Ft
6h ...(2)
Multiplying the numerator and denominator of the
right hand side by P c (circular pitch)
t2
F t P c b b
6hP c
t2
Let y
6hP c
...(3)
Where, y is called as Lewis form factor
where
h length of the tooth
b maximum bending stress
I moment of Inertia
b face width
t thickness of tooth
P c circular pitch
0.912
0.154 for 20 Involute
Z
0.95
0.175 for 20 Involute subteeth
Z
Effective load-Calculation
To determine the tangential component of the
resultant force between two meshing teeth,
P 60
(I) M t , and
2 N 1
2M t
(II) F t
d1
We know that,
6 vm
(ii) C v , For accurately hobbed and generated
6
gears, vm 5 20 m/sec.
5.5 vm1/2
(iii) C v , For precision gears with
5.5
shaving grinding and lapping and vm 20 m/sec
1 vm
(iv) C v , For non-metallic gears.
1 0.25 vm
dN
d in mm
60 10 3
Ft Fi
0.164 V m cb F t
Fd Ft
0.164 V m 1.485
cb F t
e
c
1 1
K
E1 E2
WEAR
For gears, wear is defined as loss of material from
contacting surfaces of teeth.
2.22 Design of Transmission Systems
It is further classified as
Normal wear
Moderate wear
Destructive wear
Abrasive wear
Scratching wear, etc.
Generally, normal wear (Polishing in) does not
constitute failure because it involves loss of metal
at a rate too slow to affect performance
Moderate wear refers to loss of metal more rapid
than normal wear.
This need not necessarily be destructive and may
develop on heavily loaded gear teeth.
Destructive wear usually results from loading that
is excessive for the
lubricant
D riving
employed. to oth
P itch
The effect of circle P itch
circle
destructive wear
on the tooth profile D rive n
of an involute gear to oth
Fig:2.12
is depicted in the
Figure 2.12.
PITTING
Pitting is the principal mode of failure of rolling
surfaces. The details of the process vary with the material
and operating conditions, but in all cases, it manifests itself
by the initiation and propagation of cracks in the near
Spur Gears & Parallel Axis Helical Gears 2.23
Contact stress.
Material pouring and hardness.
Surface finish and lubrication
Contact stress was originally conceived By
“HERTZ” in 1896 whose name it is often referred to as
Hertz Contact Stress.
R2
p
pO
R1 r L
x
b
Y
Fig:2.13
F w d 1 bQk
2i
Q Ratio factor
i1 [ for external
for internal]
2Z 2
Z2 Z1
c2 sin 1 1
k
1.4 E E
1 2
Ultimate stre ss
F.O.S
Working stress
2.26 Design of Transmission Systems
Material strength
F.O.S
D esign Load
2. Steel
3. Bronze, etc.
2. Rawhide
3. Compressed paper
Tensile Brinell
IS
Material strength Hardness
Specification
N/mm 2 number
Grey Cast Iron Grade 25 250 197
Phosphor Sand Cast 160 60
Bronze Chill cast 240 70
Centrifugally 270 90
cast
Cast Steel Grade 1 550 145
Constructional St 58 580-680 160-190
steel
Plain Carbon C 60 600-700 180-200
Steel
Carbon steel C 45 700 145 Core
for C 55 720 460 Case
surface 200 Core
hardening 520 Case
Carbon steel C 14 500-750 650 Case
for case
hardening
2.28 Design of Transmission Systems
Tensile Brinell
IS
Material strength Hardness
Specification
N/mm 2 number
Direct 40 Ni 2 Cr 1 1500 44
hardening Mo 28 1000-1150 400-500
Alloy steels 30 Ni 4 Cr 1 1150 400-500
35 Ni 1 Cr 60 750-1050 400-500
40 Ni 3
Alloy Stells 17 Mn 1 Cr 95 800-1100 650 Case
for case 15 i2 Cr 1 Mo 1040 630 Case
hardening 15 900-1200 600-620 Case
13 13 Ni 3 Cr 1200-1500 600-650 Case
80 600-850 650 Case
15 Ni 4 Cr 1
15 Cr 65
Nitriding 40 Cr 2 A1 1 >660 750 - 800 Case
Alloy Steel Mo 18
HP – Horse power
d1 N 1
vm m/s
60 1000
d1 mm ; N 1 rpm
2.30 Design of Transmission Systems
[Note: 1 HP ~
750 Watts ; 1 kg f ~
10 N (Newton)]
F d F t Cv in kg f
6 vm
Cv ; vm 5 20 m/s for carefully cut wheels
6
1
5.5 vm 2 v 20 m/s for precision wheels
m
Cv
5.5
1 vm
Cv For non-metallic gears.
1 0.25 vm
F s [ b] by P c . .
[ . P c m]
[ b ] b y m
d1
P c circular pitch (cm)
Z
. .
assume b 3 to 4 times of P c [ . b 3P c o r b 4P c]
where,
but P c m ;
b~
3 m to 4 m
d
where, m module
Z
b 3 Pc
3m
b~
10 m
where, m module
d1 Z1 m
d1 N1
V m/min
m 1000 [V m in m/min and
vm in m/s]
F s [b] by P c
[ b ] b y m
0.164 V m cb F t
Fd Ft
0.164 Vm 1.485
cb F t
c Deformation factor
F t Tangential load (or) transmitted load in kg f
V m in m/min
[Choose the “c” value from PSG Data book page no:
8.53 from table 41 and 42. According to quality and module,
select e - expected error in tooth profiles - mm from Table
42 and then table 41].
For safe, F s Fd
Compare the both values
If F s F d, the design is not satisfactory, then the
values of “m ” and “b” should be increased to increase the
strength of gear tooth.
Step 13: Calculation of wear load Fw
F w d1 b Qk
Q is Ratio factor
2i
Q for external gear
i1
2i
Q for internal gear
i1
1 1
[2c ] sin
E1 E2
k
1.4
2.34 Design of Transmission Systems
Pressure angle.
To Calculate [c]
Select material and heat treatment process (surface
hardness) Refer PSG Data book P.No.8.16 assume HRC
value, take C R - value,
[c] CR HRC k cl
Module m mm 2a
m
Z1 Z2
Normal module mn mm
Transverse module mt mm
Centre distance a mm Z1 Z2
am
2
Number of teeth Z – 2a
Z1 Z iZ1
m i 1 2
Virtual number of Zv
teeth
2.36 Design of Transmission Systems
p itch circle
L in e o f a ction
Too th profile
O utside (involute)
D ia
Pre ssure
Ba se circle
a ng le
Pitch circle
W h ole depth C e nte r
d istan ce
W orking Ad de nd um
C le aran ce
d ep th
D e de nd um R o ot (to oth )
fille t
R o ot
C ircu lar too th D ia
thickness
C ircu lar
p itch
Fig: 2.14
Step 1:
75
F t HP
vm
N1 Z2 d2
i
N2 Z1 d1
Assume Z 1 20
d1 Z1 m
Z2
2 . . d1
20 . m
Z1
Z 2 40
d1 mZ1
d1 N 1 . .
vm . d1 20 m
60 1000
2.38 Design of Transmission Systems
3.14 20 m 720
60 1000
vm 0.7539 m m/s
vm ~
0.7 m m /s}
35 10 3
P ower HP [ 1 H.P ~
750 watts]
750
46.666 ~
46.7
46.7 75
Ft
0.7m
5003.57
Ft kg f
m
F d F t C v kg f
6 vm
Cv [vm 5 120 m/s, for carefully cut
6
wheels, Refer PSG Data book Pg.No. 8.51]
6 12
Cv
6
Cv 3 ;
5003.57 3
Fd
m
15070.71
Fd
m
Spur Gears & Parallel Axis Helical Gears 2.39
2
Z1
sin 2 . .
. Z 1 20
2
sin 2
20
1
sin 2
10
1 1
sin
10
18.43 ~
20
0.912
y 0.154 For 20 involute
Z1
(from PSG Data book pg: 8.50)
0.912
0.154 0.1084
20
F s 10892.0320 m 2 kgf
2.40 Design of Transmission Systems
15070.71
10892.0320 m m
m
m 3 1.378
m 1.112 cm
m 11.12 mm (1 cm 10 mm)
(Choose module with nearest standard value from
Table 1 P.S.G Data book pg no: 8.2]
m~
12 mm
m 12 mm
b 10 m
10 12
b 120 mm
d1 Z1 m
20 12
240 mm
d1 N 1
vm v1
60 1000
Spur Gears & Parallel Axis Helical Gears 2.41
v1 9.0432 m/s
F s [ b] b y P c
12 12
3200 10
10 0.1084 10
15692.4815 kg f . . 12
[ . Pc m
10
y 0.1084 ; b 10 m in cm ]
Step 11: Calculate the Buckingham’s Dynamic load Fd
0.164 Vm cb F t
Fd Ft
0.164 V m 1.485
cb F t
v 9.0432 m/s
V m 9.0432 60 m/min
542.592 m/min
b 120 mm
12 c m
5003.57
Ft kg f
m
5003.57
kg f
12
416.96 kgf
Ft ~
417 kg f
2.42 Design of Transmission Systems
Choose the “c” value from PSG Data book pg no: 8.53
table: 41 and 42.
e 0.064
c 11860 e
11860 0.064
759.04
0.164 V m cb F t
Fd Ft
0.164 V m 1.485
cb F t
8476
417 3623.5 kg f
233.92
F d 3623.5 kg f
F d 3623.5 kg f
F s 15692.481 kg f
F w d 1 Qkb
2i
d 1 240 mm 24 c m ; Q (For external gear)
i1
22
Q 1.333
21
b 120 mm 12 cm ;
1 1
[2c ] sin
E1 E2
k
1.4
20 (Assume)
1 1
9500 2 sin 20 6
6
2.15 10 2.15 10
k
1.4
k 20.509 ~
21
2.44 Design of Transmission Systems
F w d1 Q kb
F w 24 1.333 21 12
8061.98 kg f
F w 8061.98 kgf
F d 3623.5 kg f
1. Module m 12 mm
Z1 Z2 Z2
2. Center Distance a m i
2 Z1
20 40 Z 2 2 20
12
2
40
360 mm
240 mm
Spur Gears & Parallel Axis Helical Gears 2.45
d2 Z2 m
40 12
480 mm
20 2 1 12
264 mm
d c2 Z 2 2f0 m
40 2 1 12
504 mm
20 2 12 2 2
212 mm
df 2 Z 2 2f0 m 2c
40 2 12 2 2
452 mm
9. No: of Teeth: Z 1 20 ; Z 2 40
Step 16: Draw the neat sketch of spur gear.
[Refer the spur gear Fig 2.14 - Pg 2.36 Design
procedure step 16:]
Problem 2.2: Design a spur gear drive to transmit 22 kW at
1000 rpm ; Speed reduction is 2.5. The centre distance between
the gear shafts is approximately 350 mm. The materials used
are: pinion – C45, gear wheel – CI Grade 30. Design the Drive
[use Lewis and Buckingham equations].
2.46 Design of Transmission Systems
Step 1
Given data
Power P 22 kW 22 10 3 W
Pinion speed N 1 1000 rpm
Speed ratio (i) 2.5
Center distance (a) 350 mm
Pinion material C45 steel
Gear wheel material C.I Grade 30
75 . . 7
F t HP kgf . 1 watt H.P
vm 750
22 10 3
Power H.P
750
d1 N 1
vm m/s
60 1000
d1 d2
Centre Distance a
2
350 2 d 1 d2
d 1 d 2 700 mm d2 700 d1
Spur Gears & Parallel Axis Helical Gears 2.47
d2
Speed ratio (i) 2.5
d1
700 d1
2.5
d1
700 d 1 2.5 d1
700 3.5 d 1
Pitch circle dia. of pinion d 1 200 mm d 2 2.5 200
d 2 500 mm
200 1000
vm 10.466 m/s
60 1000
75
F t HP
vm
75
F t 29.333
10.466
F t 210.18 kg f . .
[ . 1 kgf ~
10 N]
F t 2101.8 N
F d F t C v kg f
6 vm
Cv
6 For vm 5 20 m/s
Here vm 10.466 m/s
6 10.466
Cv
6
C v 2.744
F d 210.18 2.744
2.48 Design of Transmission Systems
F d 576.733 kg f
0.1357 gear
Spur Gears & Parallel Axis Helical Gears 2.49
F s gear [ b2] b y2 Pc
800 3 m 0.1357 m
. .
3214.33 m m . b 3Pc
3214.33 m m 576.733 Pc m
576.733
m2 m module
3214.33
m
0.179425
m 0.4235 cm
m 4.2 mm
3m
35
47.12 ~
50 mm
d 2 50 5
d 2 250 mm
d2 N 2
v2 . . N1
. i
60 1000 N2
N 2 400 rpm
50 5
800 0.1257
10 10
F s 852.196 kgf
Spur Gears & Parallel Axis Helical Gears 2.51
0.164 V m cb F t
Fd Ft
0.164 V m 1.485
cb Ft
b 5 cm ; F t 210.18 kg f
8150 0.025
203.75
vm 10.466 m/s
V m 10.466 60 m/min
627.96 m/min
0.164 V m cb F t
F d Ft
0.164 V m 1.485
cb F t
210.18 816.29
F d 1026.47 kgf
2.52 Design of Transmission Systems
F s 852.196 kg f ; Fd 1026.47 kg f
b 10 m
b 60 mm
6
800 6 0.1357
10
F s 1227.162 kg f (1)
0.164 V m cb F t
Fd Ft
0.164 V m 1.485
cb F t
147545.1802
210.18
159.19
F d 1137.02 kg f (2)
By comparing F s and F d,
Fs Fd
F w d1 Qkb
b 6 cm
d1 200 mm 20 cm
2i
Q
i1
2 2.5
Q
2.5 1
1.4285
1 1
[2c ] sin
E 1 E2
k
1.4
20 Assum e
c 5000 kgf/c m2
[From PSG Data Book pg: 8.5 table:7; for C45 steel]
1 1
5000 2 sin 20 6
6
k 2.15 10 1.46 10
1.4
2.54 Design of Transmission Systems
F w d 1 Qkb
F w 20 1.4285 7.023 6
1205.304 kg f
F w 1205.304 1137.02 F d
1. Module 6 mm
Z1 Z2
2. Centre Distance (a) m
2 Z 1 20
20 50 Z 2 50
6
2
210 mm
d1 6 20
Spur Gears & Parallel Axis Helical Gears 2.55
d1 120 mm
d2 m Z 2 6 50
d2 300 mm
d f1 20 2 1 6 2 1.5
105 mm
d f2 Z 2 2f0 m 2c
50 2 6 2 1.5
285 mm
20 2 1 6 132 mm
d c2 Z 2 2f0 m
50 2 6 312 mm
Step 1
Given data: Distance between the shafts (Centre
Distance) a 500 mm
TorqueNormal 500 N m
625 Nm
625 10 3 N mm
N2 900
i 4.5
N1 200
i 4 ; pinion (material) C 45
Pinion strength b y1
1
steel]
2
2
17.09 ~
18
sin 20
y 1 0.1033
144.66 kg f/cm 2
Gear strength b y2
2
0.192
y2 0.154
Z2
(for 20 involute)
2.58 Design of Transmission Systems
Z2
i
Z1
Z 2 4.5 18
Z 2 81
0.192
y 2 0.154
81
y 2 0.1516
485.12 kg f/cm 2
75
F t HP kg f
vm
d1 N1 2 N1 T max
vm P
60 1000 60
d1 d2 2 900 625
a
2 60
d1 d2 P 58875 Watts
500
2
d1 d2 1000 58875
P H.P
750
d2 1000 d 1 78.5 H.P
Spur Gears & Parallel Axis Helical Gears 2.59
d2 1000 d1
i 4.5 4.5
d1 d1
1000 d1 4.5 d1
1000 4.5 d1 d1
5.5d1 1000
d1 181.818 mm
d2 1000 d 1
1000 181.818
d2 818.1818 mm
d 1 N1
vm
60
181.818 900
vm
60 1000
vm 8.5636 m/s
75
F t 78.5
8.5636
F t 687.7 kg f
F d F t C v kg f
3 vm
Cv
3 [vm 8.5636 ]
C v 3.8545
2.60 Design of Transmission Systems
2643.44 kg f
m 2 0.5821 Pc m
m 0.7629 cm y1 lewis form
m 7.629 mm factor for pinion
y1 0.1033
m~
8 mm (Standard module from Data book pg: 8.2;
table: 1).
2a 2 500
m 10.1010 (for standard value)
Z1 Z2 18 81
m 10 mm
b 10 m
10 10
b 100 mm
d1 Z1 m
18 10
d1 180 mm
d2 Z2 m
81 10
d2 810 mm
Answer
(a) Module m 10 mm
Given
10
Gear ratio (or) speed ratio (i) 10
1
Power P 50 kW 50 10 3 W
2
Z1
sin 2 22.5
2
2
sin 22.5
13.6 ~
14
Z 1 14 teeth
d1 d2
a
2
d1 d2
660
2
2 660 d1 d2
d1 1320 d 2
d2
i
d1
d2
10
1320 d 2
13200 10d2 d2
13200 11d2
d2 1200 mm
d1 1320 1200
d1 120 mm
120
m 8.57 ~
8
14
m 8 mm (Standard module from Data book pg: 8.2
Table: 1]
2.64 Design of Transmission Systems
d1 120
Z1
m 8
Z 1 15
Z2
i ; Z 2 10 15
Z1
Z 2 150
Ft
Fn
cos F t tangential load
To find Ft
75
F t HP
vm
d1 N 1 120 1800
vm
60 1000 60 1000
vm 11.3040 m/s
Power 50 kW
50000
H.P
750
Spur Gears & Parallel Axis Helical Gears 2.65
66.666 75
Ft
11.3040
F t 442.32130 kg f
Ft
Fn
cos
4423.2130
cos 22.5
Fn 4787.6512 N
Fn
b
un it load
4787.6512
175
b 27.358 mm
1832.154 N
1.832 kN
Fr 1.832 kN
2.66 Design of Transmission Systems
Given Data:
Power P 20 HP
Speed reduction i 3
. .
Assume, b Face width 3P c 3m ; [ . P c m]
where m module in cm.
Spur Gears & Parallel Axis Helical Gears 2.67
[b] 3 2 m 2 y
0.684 0.684
y Lewis form factor 0.124 0.124
Z1 25
1
[ 14 involute]
2
y 0.09664
6 vm
Cv when vm 20 m sec (carefully cut gears)
6
6 19.634 m
6
76.398 6 19.634 m
Dynamic Load Fd F t C v
m 6
12.733 6 19.634 m
Fd
m ... (2)
2.68 Design of Transmission Systems
F s F d o r F s Fd
12.733 6 19.634 m
5722.79 m 2
m
449.44 m3 6 19.634 m
Trial 1: m 0.5 cm
Take m 0.3cm 3 mm
module m 3 mm
b 28.274 mm
Spur Gears & Parallel Axis Helical Gears 2.69
76.398 76.398
Ft 254.66 kg f
m 0.3
V m 19.634 0.3 60 353.412 m min
b face width 2.8274 cm
carefully c ut gears e 0.025 mm
c 11440 e 11440 0.025 [Ref PSG Data book
286 kg f cm Pg.No 8.53 Table 4.2]
0.164 353.412 286 2.8274 254.66
F d 254.66
0.164 353.412 1.485
286 2.8274 254.66
61628.2
254.66 254.66 579.31
106.382
Fd 833.97 kg f
F s 5722.79 m 2
Fs Fd,
76.398 76.398
Ft 152.796 kgf
m 0.5
b 3 m 3 0.5 4.712
0.164 589.02 286 4.712 152.796
Fd 152.796
0.164 589.05 1.485
286 4.712 152.796
144940
190.995 1131.43 kg f
154.12
F s 5222.79 0.5 2 1430.69 kg f
Here F s F d satisfied.
d1 m Z 1 0.5 25 [ c] C R HRC K Cl
12.5 mm 1.25 c m
2i 23 6 Assume alloy steel, case
Q 1.25
i1 31 4 hardened
b 4.712 c m C R 280; HRC 55 to 63
sin 1 1 take HRC 60
k [c]2
1.4 E 1 E 2 assume life 10,000 hrs.
Life N 10,000 60 1500
90 10 7 cycles
Pressure angle 14.5 K Cl 0.585
Pinion and wheel are made of [c] 280 60 0.585
same material
9828 kgf cm2
E 1 E 2 2.15 10 6 kg f cm 2
Spur Gears & Parallel Axis Helical Gears 2.71
sin 14.5 1 1
k 9828 2 6
6
1.4 2.15 10
2.15 10
16.069 kgf cm 2
F W 1419.69 kgf
Given Data:
Power P 120 HP
Module m 10 mm 1 cm
E 2 10 6 kgf/cm 2
Step 2
75
Transmitted load F t HP
vm
75
120
6.283
1432.43 kg f
F t 1432.43 kgf
Spur Gears & Parallel Axis Helical Gears 2.73
vm me an velocity in m/sec
d 1N 1 Z 1mN 1
60 100 60 100
20 1 600
But d1 mZ 1
60 100
V m 371.99 m/min
b 9.424 cm
c 11860 e ; e 0.09
701061.15
1432.43
220.196
1432.43 3183.80
F d 4616.235 kg f
2.74 Design of Transmission Systems
But F S 6418.66 kg f
FS 6418.66 Fd 4616.235
sin 1 1
k [ c ]2
1.4 E 1 E 2
E 1 E 2 2 10 6 kg f/cm 2
To calculate [ c ]
HRC 55 to 63 C R 280
Take HRC 60 Assume life 10,000 hrs
[ c ] C RHRC Kcl N 10,000 600 60
280 60 0.585 36 10 7 cycle
9828 kg f/cm 2 From PSG Data book table
(17) P.No. 8.17
K cl 0.585
pressure angle 20
Spur Gears & Parallel Axis Helical Gears 2.75
sin 1 1
k [ c ]2
1.4 E E2
1
sin 20 1 1
9828 2
1.4 2 10 6 2 106
k 23.59 kg /cm2
Wear load F w d 1 Q k b
But F d 4616.235 kg f
FW 113.9 Fd 4616.235
Since F S F d and F W F d,
Design Procedure
Step 1: Selection of material (Refer PSG Data book Page
No 8.4)
Note (a): If the material for both pinion and wheel are
same, then design for pinion alone. (because the pinion is
weaker than Gear).
...... cycles
N ..... 10 7 cycles
1.4 kbl
[b] 1
n k
1. Material
2. Surface hardness (always 350
3. Life in No. of cycles N
n factor of safety - From PSG Data book Page No.
8.19; Table: 20
Spur Gears & Parallel Axis Helical Gears 2.79
1. Material
2. Mode of Manufacture
3. Heat treatment.
k fillet stress concentration fa ctor -
From PSG Data book Page No. 1.9 (for C15, C20, C15
Mn 35, C40, C45)
From PSG Data book Page No. 1.13 to 1.15 (for alloy
steels)
From PSG Data book Page No. 1.4 (for cast iron) (only
u value)
2.80 Design of Transmission Systems
1. Wheel material
2. Heat treatment process
3. Surface hardness.
HB - Brinell hardness number
kcl - Life factor - From PSG Data book Page No. 8.17
Table: 17
10 2
Take the value of kcl , based on Ka ;
N
N -no. of cycles
1. Material
2. Surface hardness (consider surface hardness
generally 350 HB
3. Life in number of cycles N
Spur Gears & Parallel Axis Helical Gears 2.81
[M t] Mt k kd
kW hp
97420 71620
n n
2
3 0.74 E [M t]
a i 1 [ ]
c i
i Gear ratio
b
a
Z2
Since, i ,
Z1
2a
m
Z1 Z2
m Z 1 Z 2
a
2
d1 N 1
v in metres where
60
d1 pitch circle diam eter of pin io n in m eters m
N 1 speed of the pinion in rpm
d1
But m module
Z1
Calculate d1 in mm and convert into m.
Cylindrical
IS Quality depends on (1) type of gear Straight bevel
Spiral bevel
b
Page No. 8.15, Table: 13 k values depends on P
d1
kd value depends on
1. IS Quality
2. Pinion surface hardness
3. Pitch line velocity
4. Spur, helical, straight bevel and Spiral bevel
Read the value of k d.
[M t] M t k k d
i1
b [M t] [b] From PSG Data book
amby
Page No. 8.13
a centre distance in c m
Spur Gears & Parallel Axis Helical Gears 2.85
m module in cm
b face width in cm
Value of y depends on
i1 i1
c 0.74
a
ib
E [M ] [ ]
t c
If b [ b] and
Solution
Material Given: pinion C15 Steel
Z2
i.e. Gear ratio i 2.5
Z1
Power P 22.5 kW
E 2 1.4 10 6 kg f /cm 2
E 1.7 10 6 kg f /cm 2
Since u 28 kg f/mm 2
2
kg f cm 2 N
u 30 kg f /mm
10 mm 2
1.4 kbl
Design bending stress [ b] 1
n k
n Factor of safety
u 37 to 49 kgf/mm 2
y 24 kg f/mm 2
y 24 100 kgf/cm 2
2100 kg f /cm 2
Spur Gears & Parallel Axis Helical Gears 2.89
1.4 kbl
[b]
n k 1
1.4 1
2100 1225 kg f/cm 2
2 1.2
HRC 60 assumed
[M t] Mt kd k
kW
M t 97420
n
97420 22.5
900
2435.5 kg f cm
kd k 1.3
[M t] 316615 Nmm
3 2
0.74 E[M t]
Centre distance a i 1 [ ]
c i
i 2.5
b
a
b
Assume 0.3 from P.No. 8.14 table (10);
a
3 2
0.74 1.7 10 6 316615
a 2.5 1
772.2 2.5 0.3
a 142.74 mm;
Z2
Speed reduction i
Z1
2.5 25
62.5 teeth
Take Z 2 63 teeth
2a
Take, Module m
Z1 Z2
2 142.74 285.48
3.24 m m
25 63 88
2.92 Design of Transmission Systems
module 4 mm
Centre distance
b
value already assumed as 0.3 but 0.3
a
4 25 100 mm
4 64 252 mm
d1 N 1
v m/sec
60
900
0.1 4.712 m/sec
60
Spur Gears & Parallel Axis Helical Gears 2.93
60
0.6
100
kd 1.4
[M t] M t k d k
M t 2435.5 kg fc m
[M t] 351199 Nmm .
2.94 Design of Transmission Systems
i1
b [M t] [ b]
amby
[M t] 351199 N mm
i 2.5
a 200 mm
m 4 mm
b 60 mm
y form factor
for Z 1 25; X 0 ;
y 0.4205
2.5 1
b 351199
200 X 4 60 0.4205
i1 i1
c 0.74 E [M ] t
ib a
Spur Gears & Parallel Axis Helical Gears 2.95
2.5 1 2.5 1 5
0.74 1.7 10 351199
200 2.5 60
Life of Wheel
N pinion 54 10 7
N Wheel 21.6 10 7 cycles
2.5 2.5
C B HB k cl
HB 260
10 7
10 7
6 6
0.5992
N 21.6 10 7
2.96 Design of Transmission Systems
358.3216 N/mm 2
c 483.34 [ c] 358.3216
Select C40 - Surface hardened 10 7
N
HRC 40 to 55
= 0.5992
Assume HRC 50 ; C R 230 ;
kcl 0.5992
b y1 b y2
1 2
1.4 k bl
1
k n
b [b]2
2 wheel at Z 63 ; x 0 by interpolation.
Find [b]2
wheel
1.4 1
[b] wheel 2825
2.5 1.5
Pinion: Wheel
b 77.49 N/mm 2 b Induced ben ding stres s
2
1
(to be calculated)
y1 0.4205 y2 0.4927
b y 1 b y 2
1 2
77.49 0.4205
b
2 0.4927
66.13 N/mm 2
Given Data:
Power to be transmitted 18 kW
8 365 3
8760 hrs
Spur Gears & Parallel Axis Helical Gears 2.99
Step 1
Selection of material
Surface hardness 55 to 63
HRC 55 to 63
Assume HRC 60
Step 3
Refer PSG Data book pg. 8.14 Table (9)
for steel (both pinion and gear)
E eq. 2.15 10 6 kg f cm 2
Step 4
Calculation of Design bending stress [b]
Refer PSG Data book P.No. 8.18
1.4 kbl
[b] 1
n. k
350 BHN
n2
0 0.1
1 0.35 u 1200
u 155 kgf mm 2
6800 kg f cm 2
[b] 3966.66 kg f cm 2
Step 5
Calculation of design contact compressive stress [ c]
P.No. 8.16
280
N 63.07 10 7 cycles}
kcl 0.585
C R HRC . k cl
280 60 0.585
[ c] 9828 kg f cm2
Step 6
Calculation of Design torque (or) twisting moment)
M t kd k
kW
97420
n
Spur Gears & Parallel Axis Helical Gears 2.103
18
97420 1461.3 kg f cm
1200
Step 7
2
3 0.74 E [M t]
a i 1 [ ] i
c
i 35
[c] 9828 kg f cm 2 (+) for external
2
3 0.74 2.15 10 6 1899.69
a 9828
3.5 0.3
Step 8
Z2
i
Z1
Z 2 20 3.5 70 teeth
2.104 Design of Transmission Systems
Step 9
Calculation of module (Refer PSG Data book P.No.
8.22)
2a 2 125
Module m 2.77 mm
Z 1 Z2 20 70
m Z 1 Z 2
a
2
3
20 70 135 mm
2
b
0.3
a are given in Pg. 8.14, table 11
PCD of pinion d1 mZ 1 3 20 60 mm
Spur Gears & Parallel Axis Helical Gears 2.105
d1 N1 60 1200
v 3.769 m/sec.
60 1000 60 1000
Preferred Quality IS 8
b
Cal. of p
d1
40.5
p 0.675 0.8
60
IS 8 Quality, at p 0.8
k 1.06
2.106 Design of Transmission Systems
[M t] M t kd k M t 1461.3 kgcm
[M t] 2168.5692 kgfcm
i 3.5 ;
a 135 mm 13.5 cm
m 3 mm 0.3 c m
b 40.5 mm 4.05 cm
y form factor - From PSG Data book P.No. 8.18
table (18)
addendum modification coefficient x 0
Spur Gears & Parallel Axis Helical Gears 2.107
y 0.389
3.5 1
b [2168.5692 ]
16 0.3 4.05 0.389
Given Data
Power P 8 kW ; Pinion speed n N 1 764 rpm;
Solution
Since the gears are of same material, design only
pinion
HRC 40 to 55
Step 2
Life required 10,000 Hrs 10,000 60 764
Step 3
Calculation of Equivalent Young’s Modulus
Step 4
Calculation of design bending stress [ b]
1.4 kbl
[ b] 1
n k
kbl 1
k 1.5
Spur Gears & Parallel Axis Helical Gears 2.109
1 0.25 u y 500
n 2.5
1.4 1
3175 kg f/cm 2 1185.33 kgf/cm 2
2.5 1.5
[ b] 118.53 N /mm 2
Step 5
Calculation of Design surface (contact
compressive) stress [ c]
[c] C R HRC k cl
C R 230, HRC 55
[ c] 740.02 N/mm 2
Step 6
Calculation of design torque [M t]
[M t] M t k d k
kW 8
where M t 97420 97420 1020 kg f cm
n 764
[M t] 132600 Nmm
Spur Gears & Parallel Axis Helical Gears 2.111
2
3 0.74 E [M t]
a i 1 [ ]
c i
b
Here
a
Assume 0.3
2
3 0.74 2.15 10 6 1326
a 2 1 7400.2
2 0.3
a 10.865 cm a 108 mm
Z2
Speed reduction i
Z1
i Z1 2 25 50 teeth
Take Z 2 50 teeth
2.112 Design of Transmission Systems
2a 2 108
Take module m 2.88 mm
Z 1 Z 2 25 50
a 125 mm
b
but 0.3
a
d 1 75 mm 0.075 m
d 2 150 mm 0.150 m
Spur Gears & Parallel Axis Helical Gears 2.113
d1 N 1 0.075 764
v 3 m /s
60 60
IS quality 8
b
k depends upon p value
d1
37.5
p 0.5
75
Corresponding to p 0.5
k 1.03
kd 1.4
i1
b [M t] [ b]
amby
For Z 1, X 0
y 0.4205
21
b 140784
125 3 37.5 0.4205
i1 i1
c 0.74
a
ib
E [M t]
21 21
0.74
125
2 37.5
2.15 10 5 140784
Solution
Given data
Speed of driver N 1 1500 rpm
Po wer P 15 kW
Gear Ratio i 3
Step 1
Selection of material (from P.S.G Data book Pg.No.
8.5)
140 N/mm 2
500 N/mm 2
2.116 Design of Transmission Systems
Step 2
Calculation of design torque [M t]
[M t] M t kd k 1.25
kW
But M t 97420
N1
15
97420
1500
974.2 kg f cm
kd k 1.3
1583.07 kgfcm
[M t] 158307 Nmm
Step 3
Calculation of Approximate centre distance ‘a’ from
P.S.G Data book, Pg.No. 8.13
2
3
0.74 E [M t]
a i 1 [ ]
c i
2.15 10 5 N/mm 2
b
Assume 0.3 (from P.S.G Data book, Pg.No.
a
8.14)
2
3 0.74 2.15 10 6 15383.07
a 3 1
500 3 0.3
a 17.436 cm
a 174.36 mm
Step 4
Calculation of Z 1 and Z 2
Z1 25 assume
since i3
Z2
speed reduction i
Z1
3 25
75 teeth
Step 5
Calculation of module
2a
module m
Z1 Z2
2 174.36
25 75
3.48 mm
Module m 4 mm
Step 6
Recalculate centre distance ‘a’ and rounded to R10
series
m Z 1 Z2
a
2
4 25 75
2
a 200 mm
Step 7
Calculation of face width b
b
but 0.3
a
60 mm
Step 8
Calculation of PCD d 1 and PCD d2
Spur Gears & Parallel Axis Helical Gears 2.119
4 25
100 mm
4 75
300 mm
Step 9
Calculation of pitch line velocity v
d1 N 1
v m/s
60
0.1 1500
7.85 m/s
60
Step 10
Find load concentration factor k from P.S.G Data
book, Pg.No. 8.15
b
k depends on p value
d1
60
0.6
100
Step 11
Dynamic load factor kd
kd 1.4
Step 12
Recalculate, [M t], design hoisting moment
[M t] M t kd k 1.25
1755.99 kg f cm
M t 175599 Nmm
Step 13
Check b induced bending stress
i1
b [Mt] [ b]
amby
31
[175599 ]
200 4 60 0.4205
y 0.4205 ]
Step 14
Check c, induced surface stress
i1 i1
c 0.74
a
b
E [M ] [ ]
t c
Spur Gears & Parallel Axis Helical Gears 2.121
E 2.15 10 6 kg f/cm 2
4 4 6
c 0.74 2.15 10 1755.99
200 3 60
Design is safe
Step 15
Check for plastic Deformation:
175.599 N m
125%
[M t]ma x Mt
100
1.25 175.599
219.49875 N m
2194.9875 kg f cm
Step 16
Check for Bending
[M t]max 2194.9875
b max b 1400
Mt 1755.99
1750 kgf cm
(Or)
Step 17
Check for wear strength
5358.525 kg f/c m2
11160 kg f/c m2
[c]max c
mn
m Fig:2.16. Helical gear
cos (no menclature)
Pm
Pn m n.
m n normal module
b face width
P n normal pitch
0.684
y 0.124 for 14 12 full depth Involute
Zv
0.912
0.154 for 20 Involute
Zv
0.95
0.175 for 20 Involute subteeth
Zv
Fd Ft Cv
6 vm
, for vm 5 to 20 m/s, carefully cut gears
6
5.5 vm
, for vm 20 m/s, precision gears
5.5
1 vm
, for non-metallic gears.
1 0.25 vm
Dynamic load
b Face width
Helix angle
d1 b Q k
Wear load, F w
c o s2 (6.16)
Q Ratio factor,
2i 2Z2
, for external gears
i 1 Z1 Z2
2i 2Z2
, for internal gears
i 1 Z2 Z1
Z2
where i velocity ratio
Z1
[ ]2 sin 1 1
c n
14 E
p E g
1
14 or 20
2
tan n
tan t
Pn
n
t
Pt
Helix angle
Z Actual number of teeth on a helical gear.
Pressure angle
Helix angle
Normal pressure angle
t Transverse pressure angle
2.132 Design of Transmission Systems
A E
Fn
D H
B F cen tre lines
o f teeth
Fr
Fa
C
Ft G
Pitch C ylinder
n h ere
(A)
A B
Fn F n cos a
Fr Fa
n
G C G
B Ft Ft
(B) (C )
Fig:2.18.
AB
sin
AG
AB F r
AG F n
BG F t
AB AG sin Fr Fn sin (1)
Adj
cos
Hyp
BG
cos
AG
BG AG cos Ft F n cos (2)
1 4
Fr Fn sin
Ft F n cos cos
Fr sin 1
F t c o s cos
tan
Fr Ft
cos
Divide the Equation (3) by Equation (4)
3 4
Fa
F t sin
Ft
Fa F n cos sin
Ft F n c o s cos
Fa sin
. . sin
Ft cos
. tan
cos
Fa F t tan
Mt F t r d
r 2
Mt
Ft
r
2Mt
Ft
d
Spur Gears & Parallel Axis Helical Gears 2.135
2 N M t
Power P
60
60 P
Mt
2 N
. .
( . Helix angle)
Step 1
Similar to spur gear Design
Step 2, Step 3 and Step 4
Similar to spur gear Design
Step 5
Calculation of strength of gear tooth F s
F s [ b] b y v Pn Pn mn
m n normal pitch
0.684
yv 0.124 for 14 12 Involute
Zv
0.912
0.154 for 20 Involute
Zv
2.136 Design of Transmission Systems
0.95
0.175 for 20 Involute stub teeth
Zv
b 10 m n
Step 6
Calculation of Normal module m n
Step 7
Calculate the value of face width (b)
b 10 m n
Step 8
Calculate the pitch circle Diameter d1
mn
d1 Z1
cos
Helix Angle
Step 9
Calculation of pitch line velocity
Spur Gears & Parallel Axis Helical Gears 2.137
d1 N 1 v for m/sec
v
60 1000
V for m/min
N 1 rpm
d 1 mm
Step 10
Recalculate the stength of gear tooth F s
F s [b] b yv m n
Step 11
Calculation of Buckingham’s Dynamic load F d
Step 12
Check for Beam strength
Step 13
Calculation wear load F w :
1 1
[2c ] sin n
d 1 Q kb E1 E2
Fw ; k
cos 2 1.4
Step 14
Checking for wear strength
For safe Design F w Fd
Step 15
Calculate the Basic Dimensions of Helical gear
From PSG Data book PN 8.22; Table: 26
Spur Gears & Parallel Axis Helical Gears 2.139
Helical and
Nomenclature Notation Units
Herringbone Gears
Module m mm 2a cos
mn
Normal module mn mm Z1 Z2
Transverse mt mm mn 2a
m1 ; mt
module cos Z1 Z2
Centre distance a mm ma Z1 Z2
a
c o s 2
Pitch diameter d mm m
d1 Z ;
or Reference cos 1
diameter mn
d2 Z2
cos
Tip diameter dc mm Z1
da1 2f0 mn
cos
Z2
da2 2f0 mn
cos
2.140 Design of Transmission Systems
Helical and
Nomenclature Notation Units
Herringbone Gears
Root diameter df mm Z1
df1 2f0 mn 2c
cos
Z2
df2 2f0 mn 2c
cos
Helix angle deg. For helical, 8 to 25
For herringbone, 8
to 25
mn Z1 Z2
cos
2a
Number of teeth Z 2a cos
Z1 ; Z2 iZ1
mn i 1
Virtual number Zv Z1 Z3
Zv1 ; Zv2
of teeth cos 3
cos3
Step 16
Draw the neat sketch of Helical gear
H e lix
H e lix a ng le
Too th
A xis
Fig: 2.17
Spur Gears & Parallel Axis Helical Gears 2.141
Step 1
Given data
power P 15 kW 15 10 3 W
Step 2
Selection of material
Step 3
Calculation of tangential load F t
75
F t HP
vm
15 10 3
power P 15 kW H.P
750
20 H.P
d1 N 1
vm
60 1000
3.14 d 1 1400
60 1000
vm 1.517 m n m/s
20 75 988.7936
Ft kg f
1.517 m n mn
Assume Z 1 20
mn Z1
d1
cos
20 m n
cos 15
d1 20.705 mn
Step 4
Calculation of Dynamic load F d
Fd Ft Cv
3 vm
Cv ;
3
3 1.517 m n
Cv
3
3 1.517 m n
F d 988.7775 mn kg f
3
Step 5
Calculation of strength of gear tooth F s
F s [b] b yv P cn b 10 m n
[b] b yv m n
0.192
y v 0.154 For 20 Involute teeth
Zv
Z1
Zv
cos 3
20
3
22.974 ~
23
cos 15
2.144 Design of Transmission Systems
F s 6460.236 m 2n
Step 6
Calculation of Normal module m n
3 1.517 m n
6460.236 m 2n 988.755
3
m 2n 0.05875 m n 0.153055
m 2n 0.05875 m n 0.153055
m n 0.4217; m n 0.3629
(- Not possible)
m n 0.4217 c m
mn ~
5 mm
Spur Gears & Parallel Axis Helical Gears 2.145
Step 7
Calculate the value of face width b
b 10 m n
10 5
50 mm
Step 8
Calculate the pitch circle diameter
mn
d1 Z1
cos
5
20
c o s 15
d 1 103.52 ~
104 mm
Step 9
Calculation of pitch line velocity
d1 N 1
vm
60 1000
vm 7.619 m/s
Step 10
Calculate the strength of gear tooth F s
F s [ b] b yv m n
[ b] 18 10 2 kg f/c m2
50 5
18 10 2 0.1143 3.14
10 10
1615.059 kgf
2.146 Design of Transmission Systems
[b] 18 10 2 kg f/cm2
Step 11
Calculation of Dynamic (Buckingham’s) load F d
Fd Ft FI
b 50 mm 5 cm
15
Choose “c” From the PSG Data book pg: 8.53 table
41 and 42.
e 0.025
c 11860 0.025
c 296.5
988.7936
Ft
mn
988.7936
5
197.758 kg f
Spur Gears & Parallel Axis Helical Gears 2.147
3
0.164 477.714 296.5 5 cos 15 197.758
F d 197.758
3
0.164 477.714 1.485 296.5 5 cos 15 197.758
116600.4643
F d 197.759
135.63
197.758 859.66
F d 1057.427 kg f
Step 12
Checking for Beam Strength
F s 1615.059 1057.427 F d
Step 13
Calculation of wear load F w
d 1 bQk
Fw
cos 2
d 1 104 mm 10.4 cm
b 50 mm 5 cm
15
2i 23
Q 1.5
i1 31
2.148 Design of Transmission Systems
1 1
[c]2 sin
E E2
k 1
1.4
20
1 1
3000 2 sin 20 6
6
2 10 2 10
k
1.4
3.078
k
1.4
k 2.1987
171.4986
cos 2 15
183.8116 kg f
Step 14
Checking for wear strength
For safe Design F w F d
Assume k 21.987 ;
Step 15
Calculate the Basic Dimensions of Helical gear
mn 5
2. Transverse module m t 5.176 mm
cos cos 15
2.150 Design of Transmission Systems
mn Z1 Z2
3. Centre Distance a
cos 2
5 20 60
207.05 mm
c o s 15 2
Z2
i Z 1 20
Z1
Z 2 3 20 60
2.25 5
11.25 mm
~
311 mm
Z1
8. Tip Diameter dc : d c Z6 mn
1
cos
20
215
cos 15
113.52
~
114 mm
Spur Gears & Parallel Axis Helical Gears 2.151
Z2
dc Z6 m n
2
cos
60
25
c o s 15
320.58
~
321 mm
Z1
9. Root Diameter df : df 2f0 m n 2 c
1
cos
20
2 5 2 11.25
cos 15
71.02 mm
~
71 mm
Z2
df 2f0 m n 2c
2
cos
60
2 5 2 11.25
c o s 15
278.08
~
278 mm
Z1 20
12. Virtual no: of teeth Z v : Z v 3
1
cos cos 3 15
22.97
~
23
2.152 Design of Transmission Systems
Z2
Zv
2
cos 3
60
cos 15
68.92
~
69
Given Data:
P 15 kW 15 10 3 Watts 20.38 HP
(HP = 736 Watts)
i 4 :1
N 10,000 rpm
1000 kgf/cm 2
b 14 m n
Step 1
F s Beam strength [ b] b yv m n
F s 1000 14 m n 0.1492 mn
75
Transmitted load F t HP
vm
When vm 20 m/sec ,
5.5
vm
Cv (precision wheels)
5.5
75
F t 20.38
125.66 m n
12.16
mn
0.95
yv 0.175
Zv
z 24
Zv 3
36.95
cos c o s3 30
yv 0.1492
2.154 Design of Transmission Systems
Z1 m n N1
vm m/sec
100 60
m n is in cm
24 m n 10,000
100 60
vm 125.66 m n m/sec
V m 7539.82 m n m/min
Dynamic load Fd Ft Cv
5.5 vm 5.5
125.66 mn
Cv
5.5 5.5
12.16 5.5
125.66 mn
Fd
mn 5.5
2.2115
5.5
125.66 mn 2
mn
Trail 1
Assume m n 0.5 cm
LHS RHS
Not satisfactory.
Trail 2
m n 0.3 cm
L HS 80.162 ; RH S 11.639
LHS RHS
Not satisfactory.
Trail 3
m n 0.2
LHS RHS
Not satisfactory
Trail 4
m n 0.15 c m
LHS RHS
0.15 cm
mn 1.5 mm
2.156 Design of Transmission Systems
mn 1.5
m 1.732 mm
cos cos 30
b 24.24 mm
Problem 2.20: A helical cast steel gear with 30 helix angle
has to transmit 45 HP at 1500 rpm; If the gear has 24 teeth,
determine the necessary module, pitch diameter and face width
for 20 full depth teeth. The static stress for cast steel may be
taken as 560 kg cm2. The width of face may be taken as 3
times the normal pitch. What could be the end thrust on the
gear? The tooth factor for 20 full depth involute gear may be
0.912
taken as 0.154 ; where TE represents the equivalent
TE
number of teeth. (Apr. 2009)
Given Data:
0.912 0.912 T1 24
yv 0.154 0.154 TE
TE 37 3
cos cos 3 30
Beam strength FS [ b] b yv pn
[ b] 3 m n yv m n
560 3 m n 0.1293 m n
Dynamic Load F d F t C v
75 d1 N1 Z1 m n N1
F t HP vm
vm 60 100 60 100
24 m n 1500
60 100
75 18.84 m n m sec
F t 45
18.84 m n
179.14 6 vm 6 18.84 m n
kg Cv
mn 6 6
(Carefully cut gears)
179.14 6 18.84 m n
Dynamic Load F d
mn 6
29.856
Fd 6 18.84 mn
m n ... (2)
To find normal module (mm), Equate the equations
(1) and (2)
29.856
2143.91 m 2n 6 18.84 m n
mn
71.808 m 3n 6 18.84 m n
2.158 Design of Transmission Systems
Trail m n 0.45
normal mo d ule m n 5 mm
face width b 3 m n
35
47.12 mm
179.14 d 120 mm
or F t
mn
179.14 12 cm
0.5
358.28 kg 30 helix angle
2M t
Tangential force F t
d
Torque on d 12
mt Ft 358.28
pinio n 2 2
2149.68 kg cm
2148.6 kg.cm
Axial force F a 358.28 tan 30
Step 1
Selection of material
Step 2
Calculation of design stresses
1.4 kbl
[b] 1
n k
1 0.35 u 120
662.5 N /mm 2
N 10,000 60 1500
90 10 7 cycles
[c] C R HRC k cl
Spur Gears & Parallel Axis Helical Gears 2.161
C R 26.5
HRC 55
kcl 0.585
852.6 N/mm2
Step 3
Calculation of centre distance
2
a i 1
3 0.7 E [M t]
[ ]
c
i
from PSG Data book
Pg.No. 8.13
[M t] M t ko k d k
where
k kd 1.3 Assume
and
kW
M t 97420 from PS G Da ta book Pg.No. 8.15
N1
2.162 Design of Transmission Systems
30
97420
1500
1948.4 kg f c m
194.84 Nm
316.615 Nm
3 0.7 2.1 10 5 316.615 10 3
a 4 1 852.6
4 0.5
140.96
~
141 mm
Assuming Z 1 20 teeth
Z2 i Z1
4 20 80 teeth
2a cos
mn
Z1 Z2
2.65 mm
Spur Gears & Parallel Axis Helical Gears 2.163
m n Z1
But d1 from PSG Data book P g.N o. 8.22
cos
3 20
63.85 mm
cos 20
and
mn Z2
d2 from PSG Data book P g.N o. 8.22
cos
3 80
cos 20
255.4 mm
d1 d2
a from PSG Data book Pg.No. 8.22
2
63.85 255.4
2
159.63 mm
Step 4
Calculation of b, P a, [Mt]
d1
Pt Z1
Pa
tan tan
63.85
20
27.55 mm
tan 20
2.164 Design of Transmission Systems
0.5 159.63
80 mm
we find b P a
[M t] k o k kd M t
80
p 1.25
63.85
333.176 Nm
Step 5
Calculation of induced stresses
0.7 i 1 [Mt]
b from PSG Data book Pg.No. 8.13 A
ab mn yv
Spur Gears & Parallel Axis Helical Gears 2.165
where
Z1 20 ~
but Z eq 3
24
cos cos 3 20
0.7 4 1 333.176 10 3
b 73.52 N/mm 2
159.63 80 3 0.414
i1 i1
c 0.7
a
ib
E [M t]
4 1 41
0.7
159.63 4 80
5
2.1 10 333.176 10 3
Given Data:
Note
(If life of the gear drive is not given, then select life
N 10,000 hrs).
84 10 7 cycles
Step 3: Equivalent young’s modulus (refer PSG databook
P.No. 8.14) Since the material for the pinion and wheel is
same,
E eq 2.15 10 6 kgf /c m2
2
3 0.7 E [M t]
Centre distance a i 1 [ ] i
c
2
3 0.7 2.15 106 678.46
a 3 1
9828 3 0.3
b
assume
a
0.3
2a cos
m n Normal module
Z1 Z2
2 80 cos 10
mn 1.9696 mm
20 60
2.170 Design of Transmission Systems
m n Z 1 Z 2
a
cos 2
a 101.54 mm
b
0.3
a
Face width b 30 mm
k Load correctionfactor b 30
0.59
d 1 50.77
1.03 at 0.6 0.6
kd Dynamic load fac to r velocity upto 3 m/sec,
1.3 (For IS-8 Quality, 350 BHN surface
hardness)
[M t] Mt kd k
i1 Z1
b 0.7 [Mt] [b] Zv (Refer Data
a b mn yv cos3
book P. No. 8.22)
3 1 20
0.7 698.81 20.93 21 teeth
10 3 0.25 0.3955 cos3 10
659.64 kgf /cm2 [b] 1867 kgf/ cm2
Design is satisfactory based yv 0.3955at Zv 21 teeth
on bending stress
i1 i1
c 0.7
a
ib
E [M t] [c]
31 31
0.7
10
33
2.15 10 6 698.81
Given Data:
P 7.5 kW ;
N 1 1400 rpm;
Z2
Speed reduction i 3
Z
1
Pressure angle 20
Helix angle 10
E 2.05 10 5 N/mm2
Step 1
Calculation of design twisting moment [M t]
[M t] M t kd k.
kW
97420
n
7.5
97420 521.89. kg fc m
1400
M t 521.89 .kgfcm
2.174 Design of Transmission Systems
[M t] 521.89 1.3
678.46 kg fc m
67846 Nmm
Step 2
Calculation of approximate centre distance.
2
3 0.7 E [Mt]
a i 1 [ ] i
c
[M t] 67846 Nmm
b
0.3 assume, (for open type of Gearing)
a
2
3 0.7 2.05 10 5 67846
a 3 1
902 3 0.3
a 84.139 mm
Step 3
Assume Z 1 no. of teeth on pinion
20
Z2
Gear ratio i
Z1
Spur Gears & Parallel Axis Helical Gears 2.175
Z2
3
20
Z 2 60 teeth
Step 4
2a cos a 84.138 mm
mn
Z1 Z2 10
Z 1 20
2 84.139 cos 10
Z 2 60
20 60
2.07 mm
Step 5
Re-calculate centre distance ‘a’ From PSG Data book
P.No.8.23; table (26)
mn Z1 Z2
Centre distance a
cos 2
3 20 60
cos 10 2
121.85 mm
Step 6
Calculation of face width ‘b’
Already is assumed as 0.3
b
But
a
ba
Step 7
Calculate pitch circle dia. d1 and d 2
Step 8
60.92 1400
1000 60
4.46 m sec
Step 9
Selection of Quality, preferred Quality from PSG Data
book P.No.8.3; table (2) above 1m/sec; up to 8m/sec,
Preferred Quality- 1S6
Step 10
Calculate p and k; Refer table (14); P.No. 8.15 of
PSG Data book
b 37.5
p 0.61556
d1 60.92
Step 11
Read the value of k d :
kd 1.3
Step 12
Recalculate the design twisting mount [M t]
698.81 kg f cm 69881 N mm
2.178 Design of Transmission Systems
Step 13
i 3; a 125 mm
m n 3 mm; b 36.555 mm
0.39485
[M t] 69881 N mm
3 1 69881
b 0.7 36.2
125 36.5 3 0.39485
Step 14
i1 i1
c 0.7
a
ib
E [M t]
31 31
0.7 2.05 10 5 69881
125 3 36.555
Given Data:
Helix angle 30; P 15 kW; n N 10,000 rp m; i 4
3 [M t]
m n 1.15 cos
y v [b] m Z 1
kW 97420 15
M t 97420
n 10,000
146.13 kg f cm (Assume k d k 1.3
M t 14613 N mm
18996.9 N mm
yv form factor
Z v yv
2.180 Design of Transmission Systems
40 0.465
35 0.452
5 _ 0.013
Z1
2 ? Zv
cos 3
2 0.013
5.2 10 3 24
5
cos 3 30
for 35 0.452
36.95
for 2 5.2 10 3 37
37 0.4572
Z 1 24 teeth given
3 [M t ]
m n 1.15 cos 30
yv [b] m Z1
3 18996.9
1.15 cos 30
0.4572 100 10 24
1.195 mm
take m n 1.195 mm
mn 1.195
Module (m) 1.37 mm
cos c o s 30
Spur Gears & Parallel Axis Helical Gears 2.181
b face width 14 m
14 1.5 21 mm
Given Data
P 7.5 kW ; N 1000 rpm ; i 5
Solution
Step 1 Selection of material and heat treatment
Assume same material for both pinion and wheel.
Select Alloy steel with case hardened,
40Cr 1MO 28 material
u 70 85 kg f/mm 2;
Take u 80 kg f/mm 2
N 60 107 cycles
E eq 2.15 10 6 kg f/cm 2
1.4 kbl
[b] 1
n k
kbl 1
4000 kg f/cm 2
n F actor of safety 2
1.4 1
[b] 4000 1866.66 kgf/cm2
2 1.5
[ c] C R HRC kcl
[ c] 9828 kgf/cm 2
[M t] M t kd k
and
kW 10
M t 97420 97420
n 1000
M t 974.2 kgf cm
2
a i 1
3 0.7 E [M t]
[ ]
c
i
b
0.3
a
Spur Gears & Parallel Axis Helical Gears 2.185
2 6
3 0.7 2.15 10 1266.46
a 5 1
9828 5 0.3
a 12.57 c m
Z 2 i Z 1 5 20 100 teeth
2a cos
m n Normal module
Z 1 Z2
m n 3 mm
2.186 Design of Transmission Systems
m n Z 1 Z 2 3 20 100
a 182.77 m
cos 2 cos 10 2
mn
d1 Z 1 pitch circle dia of pinion
cos
3
20 60.92 mm
cos 10
d1 n 60.92 10 3
Pitch line velocity v 1000
60 60
v 3.189 m/s
preferred Quality - 8
Spur Gears & Parallel Axis Helical Gears 2.187
b 60
p 0.984
d1 60.92
corresponding to p 0.984
k1
kd 1.2
Z1 20
Zv 3
20.93 ~
21 teeth
cos c o s3 10
yv 0.3955
i1
b 0.7 [M t] [b]
amby
2.188 Design of Transmission Systems
5 1
0.7 1169.04
20 0.3 6 0.3955
i1
i1
c 0.7
a ib
E [M ] [ ]
t c
5 1
51
0.7
20
56
6
2.15 10 1169.04
Solution
Step 1
Material selection
15 Ni 2 Cr 1 Mo 15
L g 10,000 hrs
Step 2
Calculation of centre distance from P.S.G Data book,
Pg.No. 8.13
2
3 0.7 E [M t]
a i 1 [ ] i
c
b
0.3 (assume)
a
[M t] k k d M t
kW
M t 97420
N1
35
97420
1500
2273 kg f cm
[M t] 1.3 2273
2.190 Design of Transmission Systems
2954.9 kg f cm
[M t] 295490 Nmm
2 5
3 0.7 2.15 10 295490
a 2.5 1
950 2.5 0.3
125.39
~
126 mm
Step 3
Calculation of module
Z1 24 given
Z 2 i Z 1 2.5 24 60 teeth
2a cos
mn
Z1 Z2
m n 2.59
mn Z1 3 24
d1 83.13 mm
cos cos 30
d1 d2 88.13 207.82
a a
2 2
147.975 mm ~
148 mm
Step 4
Calculation of face width ‘b’
ba
0.3 147.975
44.39 mm ~
45 mm
ADDITIONAL PROBLEMS
April 1998
It is desired to determine the proportions of a spur
gear drive to transmit 8 kW from a shaft rotating at 1200
rpm to a low speed shaft, with a reduction of 3:1. Assume
that the teeth are 20 full depth involute, with 24 teeth of
the pinion. The pinion is made to be of 40 C 8 normalized
and gear of 30 C 8 normalized steel. Assume that the
starting torque is 130 percent of the rated torque.
April 1998
A compressor running at 360 rpm is driven by 150
kW, 1440 rpm motor through a pair of 20 full depth helical
gears having helix angle of 25. The center distance is
approximately 400 mm. The motor pinion is to be forged
steel and the driven gear is to be cast steel. Assume
medium shock conditions. Design the gear pair.
2.192 Design of Transmission Systems
October 2001
A pair of helical gears is to transmit 10 kW at 1200
rpm with a speed reduction of 4. Design the gear drive
assuming suitable material.
October 2000
Design a pair of spur gears to transmit 10 kW 1500
rpm with a gear ratio of 3. Assume same material for both
wheels. Check for plastic deformation assuming
instantaneous torque is 50% higher than mean torque.
October 1998
Design a set of helical gears to transmit 80 HP to
effect a speed reduction of 2.5:1 with pinion connected to
motor rotating at 1440 rpm. The teeth of gears are of full
depth 20 pressure angle to the normal plane. Peripheral
pitch line velocity may be limited to 600 meter per minute.
Assume gear and pinion are to be made of forged steel
having ultimate tensile strength of 6000 kg/cm 2. The pinion
is properly heat treated to obtain hardness of 240 BHN.
Assume service factor of 2 and number of teeth in pinion
16 .
Chapter – 3
3.1 INTRODUCTION
Bevel gears are used to transmit power between two
intersecting shafts. There are two types of bevel gears -
Straight and spiral. Incase of straigth bevel gears, the teeth
are straight, which converge into a common apex. Incase
of spiral bevel gears, the teeth are curved. Straight bevel
gears are easy to design and manufacture. These gears
produce noise at high speed conditions.
um
end
dum
Add
d en
De
b
PC D
( ,n sid e)
R oot
O D iam eter
PC D Tip
(O u ts ide)
D iam eter
R = C on e D is ta nce
b =Fa ce W idth
Se m i C o ne A ng le
( o r P itc h Angle) a f
a Ad dend um Angle
f D edend um A ng le Fig. 3.1. P arameter of bevel gear
o
< 90 (A cu te) o
= 9 0 (R igh t)
(a) (b)
z2
o
> 9 0 (O b tu se ) z1 M itre B evel
o
= 90 G ea rs
(c) Fig. 3.2. (d) z 1 = z 2 = no o f te e th in ea ch g e ar.
o
= 90
f
M
a
1
d1
a
f1
2 a1 a2
mt
f2
b mt
R a ha
b
mm
hf
d2 s = ab
d a2
1
R
2
d 21 d 22
1
R m
2 t
Z 21
Z 22
where
d 1 & d2 Pitch circle diameter of pinion and
gear.
Z1 & Z2 Number of teeth of pinion and gear.
1 & 2 Pitch angle of pinion and gear.
mt Transverse module
addendum ha
a tan 1 tan 1
cone distan ce R
dedendum hf
f tan 1 tan 1
cone distance R
a
3.6 Design of Transmission Systems
f
Where
ha Addendum
hf Dedendum
Design of Bevel,Worm and Cross Helical Gears 3.7
Where
Z1 & Z2 are the actual number of teeth on the
pinion and gear of the bevel gear
respectively.
Z v1 & Z v2 are the virtual number of teeth on the
pinion and gear of the bevel gear respectively.
Rb
F s [b] b m yv
R
3.8 Design of Transmission Systems
d21 d22
R
2 2
Rb
R is a bevel factor.
Fd F t F I
0.164 V m cb F t
Ft
0.164Vm 1.485
cb F t
d1 b Q v kw
Fw
cos
FT
cos
FN
FT FN c o s
3.10 Design of Transmission Systems
FN
F R V= F R FR
FR
R FT
b
F RH= F A
G ea r S ha ft
Rm
o
=p re ssu re an gle = 2 0
P itch co ne a ng le fo r p in io n
b =fac e w id th O ver H an g
R = con e distan ce D ista n ce
Fo rc es a ctin g o n
Fig. 3.4 .
B ev el G ea r
FR
sin
FN
F R F N sin
FR
tan
FT
F R F T tan
d1
R m R b/2 sin 1 ; sin 1
2R
Design of Bevel,Worm and Cross Helical Gears 3.11
d1 FR
R m R b/2 V FR
2R
FR
The radial force F R acting at the Fig. 3.5 H
FR
H
sin 1
FR
. .
. FR F T tan
F R FR sin 1
H
F T tan sin 1
FR
V
cos 1
FR
F R FR c o s 1
V . .
( . FR FT tan
F T tan cos 1
Circular tooth S S1 mt S2 S1 mt S2
thickness
3.14 Design of Transmission Systems
mt mt
S2 S2
2 2
ha1 ha2 tan 1.22 ha1 ha2
Kmt tan Kamt
b Face width
Angles
Pinion Wheel
a addendum angle a addendum angle
1 2
b sin 1
1. Transverse module m t m m
Z1
where
b face width
1 2 90
Z2
But, tan 2 i
Z1
mt Z1 m t Z2
2 sin 1 2 sin 2
R
y
b
for i 1 to 4 y 3
for i 4 to 6 y 4
Design of Bevel,Worm and Cross Helical Gears 3.17
In general, take y 3
R
3
b
R
b
3
8. Addendum angle a
m t fo
tan a tan a
1 2 R
9. Dedendum angle f
m tfo c
tan f tan f
1 2 R
Where c clearance
Z Z1
Zv ; Zv
cos 1 cos 1
Z2
Zv
2 cos 2
Step 1:
For a given problem, note down the given parameters
like, power, speed, gear ratio (i) etc...
1 2 90 ; tan 2 i
2 tan 1 i
Z2
i if Z 1 is n ot given, Assume Z 1 20
Z1
HP 75
Ft kg f
vm
[1 kgf of ~
10 Newton]
vm Pitch line velocity m/sec.
HP 75
Ft 10 N
vm
Fd Cv Nsf km Ft
b
[ b] b yv 1
R
Fs
Pd
Diametrical Pitch P d
Pd Pc Circular Pitch
Pc
d
Pc
Z
b Face width in cm
R Cone Distance in cm
10
b 0.3 R (or)
Pd
m t transverse module in cm
From PSG Data book Pg 8.52
10 Z1
b 0.3 R (or) P d1 d
Pd
1 1
d1 m t Z1
b
[ b ] b y v 1
R
Fs
Pd
b
Fs [ b] b yt 1
R
Design of Bevel,Worm and Cross Helical Gears 3.21
0.164 V m cb F t
Fd F t
0.164 Vm 1.485
cb Ft
d ib Q v kw
Fw
cos 1
1 1
[c] sin
E 1 E2
kw
1.4
. . 1
. If is not given, assume 14
2
Step 1
b
[ b] b Yv 1
R
F s Beam strength
Pd ... (1)
1
But P d diametrical pitch
P c m t mt
P c m t
Y v yv where yv virtual
form factor based on
virtual no. of teeth.
Z v
0.912 Z1
yv 0.154 for 20 involute Zv
Zv c o s 1
0.684 1 2 90
0.124 for 1412 involute
Zv
0.95 tan 2 i
0.175 for 20 involute stub
Zv
Calculate 2 and
then 1
Z v 18 for 20
involute teeth
Design of Bevel,Worm and Cross Helical Gears 3.23
b
Beam strength Fs [ b] b yv m t 1
R ... (2)
Note
If b is not given in the problem, take from PSG
databook. P.No. 8.52
10
b 0.3 R or B ut P d
Pd Pc mt
0.3 R to 10 m t
3.5 vm
For straight bevel. C v
3.5 [when vm 5 m sec ]
F t Transmitted load 75
HP
or Tangential tooth load vm
d 1 av N 1
Where vm mean velocity m sec
60 100
3.24 Design of Transmission Systems
R 0.5b
d 1 av m t Z 1
R
Calculate vm, F t and C v and substitute the values in
the equation of F d
Step 2
Buckingham’s Dynamic load from PSG Data book Pg
No 8.50
0.164 Vm cb F t
Fd Ft
0.164 V m 1.485
cb F t
(Similar to equation for the spur gear)
b face width in cm
F t transmitted load in k gf
Note
If F s F d, change the transverse module m t, and
recalculate d1 av, vm, F t, F S, b and R.
Calculate again F d and check in the 2nd trail, If
F S F d then the design is satisfactory.
Step 3
b d1 Q k d 1 PCD of
Wear load F w
cos 1 pinion.
Z 1 m t cm
Fw Fd Then the design tan 2 i
is satisfactory 90
i 2
based on wear
Cal. 1
strength
Note: If F w F d then change the k calculate as
material, Similar to spur
recalculate k Gear Design
procedure.
and calcuculate again F w
In the 2nd 2i
Q
trail i1
If F w F d
LEWIS METHOD
Solution:
Step 1:
Given Data:
Material for pinion and gear cast iron
1
Pressure Angle 14
2
55 N/mm 2
. .
[ . 1 N /m 2 10 6N/mm 2]
630 N/mm 2
Modulus of Elasticity
E 1 E 2 84 kN/mm 2 84 10 3 N/mm2
Design of Bevel,Worm and Cross Helical Gears 3.27
Step 2:
d2 100
Calculation of pitch angles i 1.25
d1 80
2 51.34
1 2 90
1 90 51.34
1 38.65
Step 3:
Selection of Materials
Pinion - Cast Iron
Step 4:
d1
Z1
mt
d1 80
Z v1
m t c o s 1 m t cos 38.65
3.28 Design of Transmission Systems
102.43
mt
d2 100
Z v2
m t cos 2 m t cos 51.34
160.07
mt
Step 5:
HP 75
Ft kgf
vm
2.75 10 3
Power 3.6666 H.P
750 d 1 mm
N rp m
d1 N1 80 1100
vm 4.6076 m/s
60 1000 60 1000
3.6666 75
Ft 59.682
4.6076
Step 6:
F d C v Nsf km F t
3.5 vm
Cv
3.5
3.5
4.6076
Cv 1.6132
3.5
F d C v N sf k m F t 1.6132 1 1 596.82
F d 962.8466 N
Step 7:
b 10
F s [ b] by v m t 1 b 0.3R (Or)
R Pd
0.684 1
yv 0.124 F or 14 involute
Zv1 2
0.684 mt
0.124
102.43
b
F s [b] m t b yv 1
R
0.3R
55 m t b 0.124 6.6777 10 3 m t 1
R
F s 287.96 m t 15.507 m 2t
3.30 Design of Transmission Systems
1
[R
2
d 21 d 22
1
2
2
80 2 100
64.03 ~
64 ]
m t 4.37 mm
d1 m t Z1 d 2 m t Z2
d1 d2
Z1 Z2
mt mt
80 100
5 5
Z 1 16 Z 2 20
Design of Bevel,Worm and Cross Helical Gears 3.31
Step 11:
v1 4.6076 m/s
Step 12:
F s 287.96 m t 15.507m 2t
mt 5
1052.125 N
Step 13:
d 1 b Q v kw
Fw
c o s 1
102.43 102.43
Zv1 20.486
mt 5
160.07 160.07
Zv2 32.014
mt 5
2 Z v2 2 32.014
Qv 1.295
Z v1 Zv2 20.486 32.014
1 1
[ 2e ] sin
E1 E2
kw
1.4
3.32 Design of Transmission Systems
2.36609
1.4 b 20 mm
kw 1.69
cos 1 cos 38.65 0.7809
d 1 b Q v kw
Fw
cos 1
80 20 1.2195 1.69
0.7809
3297.528
0.7809
F w 4222.72 N
Step 14:
Checking for Wear
Fw Fd
4222.72 N 962.84 N
The design is safe based on wear condition.
Answer
Module m 5 mm
Pinion Z1 16
Gear Z2 20
Design of Bevel,Worm and Cross Helical Gears 3.33
Problem 3.2: Design a right angle bevel gear drive with speed
of pinion shaft 300 rpm and that of the gear shaft 150
rpm; pinion is to have 20 teeth of involute profile with module
of 20 mm and a pressure angle of 20 and is to be of suitable
material. Gear is of forged steel having allowable stress of
1500 kg/cm2, kW at gear shaft 56; Assume service factor
2; (May / June - 2008)
LEWIS METHOD
Given Data:
Module m t 20 mm
Service factor 2
Z2 N1 300
i speed reduction 2
Z1 N2 150
Z 1 20 teeth
Z 2 40 teeth
3.34 Design of Transmission Systems
R cone distance (or) cone length 0.5 mt Z 21
Z 22
0.5 20
20 2 40 2
447.21 mm
134.163 mm
13.4163 cm
Step 1
b
Beam strength F s [ b ] b yv mt 1
R ... (1)
From PSG Databook, Pg No. 8.52
F S 1500 13.4163 Z1 Z2
ZV
13.4163 cos 1 cos 2
0.1438 2 1
44.721 But
12,728 kg f/cm 2 1 2 90 ; tan 2 i 2
2 63.43
Beam Strength
FS 12,728 kg f/cm 2
Design of Bevel,Worm and Cross Helical Gears 3.35
40
ZV
cos 63.43
1 90 2 26.57
89.42 90 teeth
0.912
y v 0.154
Z V gear
0.912
0.154
90
0.1438
Step 2
75
Transmitted load (or) tangential tooth load F t H P
vm
76.08 HP
d1 av N1
vm mean velocity m/sec or
60 100
d2 N2
av
m /sec
60 100
R 0.5b
d2 m tZ 2
av
R
680 mm 68 cm
68 150
vm 5.34 m /sec
100 60
3.36 Design of Transmission Systems
76.08 75
Transmitted load F t
5.34
1068.53 kgf/cm 2
0.164 Vm cb F t
Fd Ft
0.164 V m 1.485
cb F t
F t 1068.53 kg f/cm2
b 13.416 cm
52.54515388.7684
1068.53
52.545 184.216
FS Fd
Step 3
To check for wear strength,
b d 1 Qv k w
Fw
cos 1
d1 m tZ 1 20 20 400 mm 40 cm
2i 22 4
Qv 1.333
i1 21 3
1 26.57
sin 1 1
k [ c ]2
1.4 E 1 E 2
[ c ] C R H RC k cl P.No. 8.16 PSG Data book
220 60 0.6177
8153.83 kg f/cm 2
. .
. Forged steel, HRC 55 to 63
Take HRC 60
C R 220
k cl assume life 10,000 hrs Refer PSG Data book
(P.No. 8.17)
3.38 Design of Transmission Systems
N 300 60 10,000
18 10 7 cycles
6 107 6 10 7
kcl
N 18 10 7
0.6177
Take
E 1 E 2 2.15 10 6 kgf/cm 2 P.No. 8.14 PSG Data book
sin 20 1 1
k w 8153.83 2
1.4 2.15 10 6 2.15 10 6
15,109 kg/cm2
12,057 kg f/cm 2,
LEWIS METHOD
Given Data:
Pressure angle 20
i3
1000 kgf/c m2
P 37.5 kW 50.95 HP .
1 HP 736 Watts
1
Face width b Length of pitch cone
3
1
R
3
b
[b] b Yv [1 ]
R
From PSG data book, F s
Pd
(Replace Y v & P d
b
F s beam strength [b] b yv mt 1
R Yv yv
Pd
Pc m t
1
mt
3.40 Design of Transmission Systems
1 1
1000 R 0.1125 m t 1
3 3
78.539 m t R kg f
1 2 90 Z1 20
Zv 21.08 22
cos 1 cos 18.53
(assume Z 1 20 teeth
tan 2 i 3 0.912 0.912
yv 0.154 0.154
Zv 22
2 71.56 0.1125
1 18.43,
R 0.5 m t
20 2 60 2 R 0.166 R
mt
R
31.62 m t cm
d1av N 1
vm
100 60
Design of Bevel,Worm and Cross Helical Gears 3.41
F t T ransmitted load
75
50.95
6.55 m t
583.396
kgf
mt
vm 3.5
3.5
6.55 m t
Cv
3.5 3.5
Dynamic load Fd F t C v
78.53 m t 31.62 m t
Trail 1
Let m t 0.5 cm
LHS RHS
Not Satisfactory
Trail 2
Let m t 0.6 cm
LHS RHS
Not satisfactory.
Trail 3
Let m t 0.65 cm
LHS RHS
Not satisfactory
Trail 4
Let m t 0.62 cm
LHS RHS
Not satisfactory.
Design of Bevel,Worm and Cross Helical Gears 3.43
Trail 5
Let m t 0.7
LHS RHS
Not satisfactory
Trail 6
Let m t 0.72
LHS RHS
Not satisfactory
Trail 7
Let m t 0.725
LHS RHS
Therefore, select
m t T rans verse m odu le 0.725 mm 7.25 cm
Cone distance
R 31.62 m t 31.62 0.8 25.296 c m
3.44 Design of Transmission Systems
R 252.96
Face width: b 84.32 mm
3 3
Pitch diameters:
Here check F w F d
LEWIS METHOD
Solution:
Step 1:
Given Data:
Power 9 kW 9 10 3 W
Step 2:
Selection of Materials
Pinion C20 ; Gear C20
Step 3:
tan 2 i
2 tan 1 3
2 71.56 ; 1 2 90
1 90 71.56
1 18.43
Step 4:
20
21.08 ~
22
cos 18.43
Z2
i
Z1
Z 2 3 22
Z 2 66
Z2 66
Z v2
cos 2 cos 71.56
3.46 Design of Transmission Systems
Z v2 2086 ~
209
Step 5:
HP 75
Ft kgf
vm
9 10 3
Power HP
750 d 1 m tZ 1
d 1 20m t
12 HP
d 1N 1 20 mt 200
v1
60 60 1000
209.439
v1 mt m/s
100
v1 0.2094 mt m/s
12 75
Ft
0.2094 mt
4297.99
Ft kg f
mt
Step 6:
F d C v N sf k m Ft
3.5
vm
Cv
3.5
Assume vm 5 m /s
3.5 5
Cv
3.5
1.6388
1.6388 1 1 4297.99
Fd
mt
7043.553 70435.53
Fd kgf N
mt mt
Step 7:
b
F s [ b] b yv m t 1
R
u 500
[ b] 166.66 N/mm 2
3 3
R~
b 0.33 R
3
b 0.33 R
b 10.43 mt
mt
R1
2
Z 21
Z22
mt
2
20 2 60 2
R 31.62 mt
3.48 Design of Transmission Systems
0.912
yv 0.154
Zv
1 For 20 Involute 20 (Assume)
0.912
0.154
22
yv 0.1125
409.56 m 2t N
Step 8:
We know that
Fs Fd
70435.53
409.56 m 2t
mt
70435.53
m 3t
409.56
m t 3
171.978
m t 5.56 mm
mt ~
6 mm
Step 9:
b 60 mm
Design of Bevel,Worm and Cross Helical Gears 3.49
Step 10:
d 1 m 1Z1
6 20
d 1 120
Step 11:
v1 0.2094 m t m/s
1.2564 m/s
Step 12:
F s 409.56 m 2t N
409.56 36
14744.16 N
Step 13:
0.164 Vm cb F t
Fd Ft
0.164 V m 1.468
cb Ft
4297.99
Ft kgf
mt
3.50 Design of Transmission Systems
4297.99
kgf
6
716.33 kg f ~
7163.3 N
b 60 mm ~
6 cm
c 11860 0.015
c 177.9 kg f/cm
0.164 V m cb F t
Fd Ft
0.164 V m
1.468 cb F t
substitute F t in kg f
b in cm
V m m/min
vm m/s
c kg f/cm
then we obtain F d in kg f
0.164 1.2564 60177.9 6 716.33
716.33
0.164 1.2564 60 1.468 177.9 6 616.33
22052.2118
716.33
74.36
716.33 296.548
F d 1012.87 kgf ~
10128.7 N
Design of Bevel,Worm and Cross Helical Gears 3.51
Step 14:
14744.6 10128.7
The design is safe.
Step 15:
d 1bQvkw
Fw
cos 1
d 1 120 mm
b 60 mm
2Zv2 2 209
Qv 1.809
Z v1 Z v2 22 209
13729.102 N
Step 16:
Fw Fd
13729.102 10128.7 N
Step 17:
1 18.43
2 71.56
2. Addendum Angle a
mtf0
a1 a2 tan 1
R
61
tan 1
190
a1 a2 1.8 R 31.62 m t
31.62 6
~
189.72 190 mm
3. Dedendum Angle f
f0 c
f1 f2 tan 1 mt
R
6 1 0.2
tan 1
190
tan 1 0.03789
f1 f2 2.17
0 1
Design of Bevel,Worm and Cross Helical Gears 3.53
Z v2 22 ; Z v2 209
LEWIS METHOD
Solution
Step 1
Given Data
P 15 kW 15 10 3 W
Step 2:
Selection of Material
Pinion - 15 Ni 2 Cr 1 Mo 15 / steel
Gear - 15 Ni 2 Cr 1 Mo 15 / steel
Step 3:
tan 2 i 1 2 90
2 75.96 1 14.03
Step 4:
Steps 5:
HP 75
Ft kg f
vm
d1 m t Z1
15 10 3 d1 20m t
P H.P
750
P 20 H.P
Design of Bevel,Worm and Cross Helical Gears 3.55
d 1N 1 20m t 1600
vm 1.6755 m t
60 1000 60 1000
HP 75
Ft kgf
Vm
20 75
1.6755 m t
895.255
kg f
mt
Step 6:
F d Cv N sf k m F t
3.5
vm
Cv Ass ume vm ~
5 m/s
3.5
N sf 1 ; k m 1
[ both gears are straddle
mounted (Assume) ]
3.5
5
Cv 1.6388
3.5
14672.12
Fd N
mt
3.56 Design of Transmission Systems
Step 7:
[ b] 3200 kgf/cm 2
1
320 N/mm 2 1 kgf/cm 2 N/mm 2
10
320 N /mm2
1
Always Assume b R
3
mt
R
2
Z 21
Z 22
mt
2
20 2 80 2
R 41.23 mt
0.912
yv1 0.154 For 20 Involute, From PSG data
Z v1
book pg 8.50
0.912
yv 0.154 yv 0.1105
21
Design of Bevel,Worm and Cross Helical Gears 3.57
b
F s [ b] b y v1 1 m t
R
1 R
320 R 0.1105 1 mt
3 3R
41.23
320 m t 0.1105 0.666 m t
3
F s 1016.78 m 2t
Step 8:
We know that
Fs Fd
14672.12
1016.78 m 2t
mt
14672.12
m 3t
1016.78
mt ~
2.43
Step 9:
b~
38 mm R~
124 mm
3.58 Design of Transmission Systems
Step 10:
d1 mt Z 1
3 20
d1 60 mm
Step 11:
d 1 1600 60 100
vm v1l
60 1000 60 1000
5.0265 m/s
Step 12:
F s 1016.78 m 2t
1016.78 9
9151.02 N
Step 13:
0.164 V m cb F t
Fd Ft
0.164 V m 1.485
cb F t
895.255
Ft kgf
mt
298.418 kgf
Design of Bevel,Worm and Cross Helical Gears 3.59
d1 60 mm d2
i
d1
N1 d2 4 60
i
N2
N 2 N 1/i d2 240 mm
1600
4
N 2 400 rpm
d2 N 2 240 400
vm
60 1000 60 1000
vm 5.0265 m/s
b~
38 mm 3.8 cm
c 1160 0.0125
148.25 kgf /c m
To calculate F d
Substitute V m in m/min ; b in cm
F t kg f b 38 mm 3.8 cm
Then obtain F d in kg f.
3.60 Design of Transmission Systems
V m 5.0265 60 m/min
301.5 m/m in
0.164 V m cb F t
Fd Ft
0.164 V m 1.468
cb Ft
42623.70
298.418
236.11
298.418 180.52
F d 478.9 kgf ~
4789 N
Step 14:
9151.02 4789
Step 15:
d 1b Q v kw
Fw
cos 1
d 1 60 mm ; b 38 mm
2Z v2 2 330
Qv 1.8803
Z v1 Z v2 21 320
Design of Bevel,Worm and Cross Helical Gears 3.61
1 1
[2e ] sin
E E2
kw 1
1.4
20
2.15 10 5 N /mm2
e 550 N/mm2
1 1
5502 sin20 5
5
kw 2.15 10 2.15 10
1.4
0.687 N/mm2
F w 3038.3 N
Step 16:
Fd Fw
d 1 b Q vkw
Fw
cos 1
60 38 1.8803 2.5
cos 14.03
11047.26 N
Now F w F d
Step 17:
tan 2 i 2 75.96
1 14.03
2. Addendum Angle a
m t fo
tan a1 tan a2
R
31
a 1 tan 1 fo 1
124
Design of Bevel,Worm and Cross Helical Gears 3.63
a 2 a1 1.3859
m t f0 c
tan f1 tan f2 c 0.2
R
3 1 0.2
f1 f2 tan 1 29.67 10 3
124
f1 f2 1.704
f0 1
o r 55 to 63 RC
or 40 to 55 RC
Step 2
Calculate equivalent Young’s modulus.
From PSG Data book P.No. 8.14 table (9)
Read young’s modulus E 1, E2 according to the
material.
Find the equivalent Young’s modulus E eq
kg /cm2 N
f
to convert
10 mm2
Step 3
Assume life 10,000 hrs to 20,000 hrs.
Design of Bevel,Worm and Cross Helical Gears 3.65
i.e.,
N Life required Given life in Hrs RPM 60 C ycles
Step 4
modification coefficient.
kgf/cm2
Convert into N/mm 2 N/mm 2
10
Step 5
Calculate [ c ] in kg f/cm 2
Step 6
Calculation of Design torque of twisting moment
[ M t ] P.No. 8.15 PSG Data book
97420 kW
N
And [ M t ] Mt k d k in kg f cm .
[ kg f cm 100 Nmm ]
3.68 Design of Transmission Systems
Step 7
Calculate Cone distance ‘R’
2
0.72 E[ M t ]
R y 2 3
i 1 0.5 [ ] cm
i
y c
R
y table (13) From PSG Data book P.No. 8.15
b
Z2
i speed ratio
Z1
kg /cm 2
Step 8
R 0.5 m t Z 1
i2 1 (or) R 0.5 m t
Z21
Z22
Assume Z 1 20 to 30
Represent cone distance R in mm.
Calculate m t in mm
Design of Bevel,Worm and Cross Helical Gears 3.69
Step 9
b
Calculate to find (k)
d1av
To find d 1av
b sin 1
m m mav m t
Z1
From PSG Data book P.No. 8.38 table 31
d1 av N 1
m sec d1 av
60 1000
mm Z
1
Cal. d1av in mm
b
Calculate ratio .
d1 av
b
k value depends on value and surface hardness.
d1 av
3.70 Design of Transmission Systems
Step 10
Selection of IS Quality (From PSG Data book
P.No.8.3) Table 2
d1av N 1
Calculate pitch line velocity v m sec
60 1000
Step 11
Read the value of kd
Step 12
Recalculate [M t]- Design twisting moment.
[M t] M t kd k
Represent [Mt] in kg cm
Step 13
Calculation of induced bending stress b
Design of Bevel,Worm and Cross Helical Gears 3.71
R
i2 1 [M t] 1
b 2
[b]
R 0.56 b mt yv cos
yv form factor
Z1
Z eq Z v
cos 1
Step 14
Calculate induced surface contact compressive stress
c
c
0.72
R 0.5b
i2 13
ib
E [M t] [ c]
Assume
If
c [c]w heel,
wheel
Design of Bevel,Worm and Cross Helical Gears 3.73
To check b,
b induced bending
Already Z1
1
calculated Zv
stress for pinion 1 cos 1
in step 13
y v form factor for wheel
2
Z2
Zv
2 cos 2
M t twisting moment
kW
97420 kgf cm
N1 where N 1 pinio n speed in rpm
tan
Radial force F r F t
cos
2M t 2M t Where
F tav
d av b Pres sure angle 20
d1 1 0.5
R helix angle
18 to 25
Design of Bevel,Worm and Cross Helical Gears 3.75
F tav
tan cos sin av sin
c o s av
Axial force F a
F tav
tan sin sin av c o s
cos av
35 preferred
reference angle
1 90 2
sin
tan 1
i cos 1 2
sin 180
tan 1
i c o s 180
3.76 Design of Transmission Systems
Gear ratio : 3
Material for pinion and gear : C45 steel
Life : 10,000 hrs.
(May/June 2013)
HERTZ METHOD
Given data
P 7 kW ; N 1600 rpm ; i 3 ; N 10,000 hrs
Solution
Selection of material
Since the given material for pinion and wheel are
made of same material (i.e) C45 steel, therefore, design only
pinion.
1.4 kbl 1
[b]
n k
kbl 1
u 63 71 kgf/mm 2; y 36 kgf/mm 2
Assume
n 2.5
k 1.5
3.78 Design of Transmission Systems
1.4 1 3150
1176 kg f/c m2 117.6 N/mm 2
2.5 1.5
C R 230
HRC 50
N 25 10 7
kcl 0.585
[M t] M t kd k
kW 7
But M t 97420 97420 426.21 kgf cm
n 1600
2
0.72 E [Mt]
i2 1
3
R y 0.5 [ ] i
y c
for i 3, Assume y 3
2 5 2
0.72 2.15 10 554.07 10
2 3
R3 3 1 3 0.5 672.75
3
R 97.67 mm
R 0.5 m t Z1
i2 1
Assume Z 1 20 teeth
m t 3.08 mm
m t 5 mm
R
y 3
b
R 158.113
b
3 3
b 52.7 mm
b
Step 10: Calcualtion of k and
d 1av
From PSG Data book, Pg.No. 8.15, Table 14
Average module
sin 1
m av m t b
Z1
but
tan 2 i 3
m av 4.16 mm
But
b 52.7
0.6323
d 1av 83.33
k 1.6
d1av N
Pitch line velocity v
60 1000
83.33 1600
v 6.98 m/s
60 1000
kd 1.4
[M t] 95471 Nmm
R
i2 1 [Mt] 1
b [ b]
2
R 0.5b b mt yv cos
3.82 Design of Transmission Systems
0.72
i2 13
c E [M t]
R 0.5b ib
0.72
158.113 0.5 52.7
3 2 13
3 52.7
2.15 10 954715
HERTZ METHOD
Solution
Given data
Power P 25 kW
Z 1 30 teeth
N1
i 1.54
N2
Step 1
Selection of material
Step 2
Calculation of Design torque [M t]
[M t] M t kd k
3.84 Design of Transmission Systems
But
kW
M t 97420
N1
25
97420
1200
2029.58 kg fcm
From P.S.G Data book, Pg.No. 8.15
kd k 1.3 assume
[M t] 2029.58 1.3
2638.45 kg fcm
263845 Nmm
Step 3
Calculate cone distance ‘R’
2
0.72 E [M t]
2 3
R y i 1 0.5 [ ] i
y c
R
y 3 correspon ding to i 1 to 4
b
i 1.54
2 5
0.72 1.7 10 263845
R3
1.54 1 2 3
3 0.5 [750] 1.54
89.54 mm
Design of Bevel,Worm and Cross Helical Gears 3.85
Step 4
Calculation of transverse module “m t”
R 0.5 m t Z 1
i2 1
89.54 0.5 m t 30
1.542 1
m t 3.25 mm
Step 5
Recalculate ‘R’ and calculate ‘b’
R 0.5 m t Z 1 i2 1
0.5 4 30
1.542 1
110.17 mm
R
But y 3 assumed
b
R 110.17
b 36.72 mm
3 3
Step 6
Calculation of load concentration factor ‘k’
b
From P.S.G Data book, Pg.No. 8.15, b
d 1av
sin 1
m av m t b
Z1
we know that
tan 2 i
1 90 57 33
36.72 sin 33
m av 4
30
3.33 mm
but
b 36.72
0.3672
diav 100
k 1.6
Step 7
Calculate pitch line velocity v
Step 8
Calculate the value of k d
Design of Bevel,Worm and Cross Helical Gears 3.87
Step 9
Recalculate design twisting moment
[M t] Mt kd k
2029.58 1.4 16
4546.25 kgfcm
454625 N mm
Step 10
Calculation of Induced bending stress b
R
i2 1 [M t] 1
b 2
[ b]
R 0.5b b m t yv cos
Z1 30 30
Zv 35.77
cos 1 cos 1 c o s 33
~
36 teeth
y v 0.4546 at value X 0, Z v 36
110.17
1.542 1 45462.5 1
b 2
110.17 0.5 36.72 86.72 4 0.4546 cos 20
91,967,564.61
173.89 N /mm 2 [ b] 80 N/mm 2
528,880.904
3.88 Design of Transmission Systems
Trail 1
Assume m t 5
Step 5
R 0.5 m t Z 1
i2 1 137.71 mm
R 137.71
b 45.90 mm
3 3
Step 6
sin 1
m av mt b
z1
sin 33
5 45.90
30
m av 4.166 mm
but
d1av Z1 m av
30 4.166 120 mm
b 45.90
0.375
d1av 120
k 1.6
Design of Bevel,Worm and Cross Helical Gears 3.89
Step 7
d1av N 1 120 1200
v
60 1000 60 1000
7.539 m/s
Step 8
kd 1.4 for v upto 8 m/s
Step 9
[M t] M t kd k
4546.25 kg fcm
454625 Nmm
Step 10
R
i2 1 [M t] 1
b 2
R 0.5 b b mt yv cos
Trail 2
Assume m t 6
Step 5
R 0.5 m t Z 1
i2 1
3.90 Design of Transmission Systems
0.5 6 30
1.54 2 1
165.25 mm
R 165.25
b 55.08 mm
3 3
Step 6
sin 1
m av mt b
Z1
sin 33
6 55.08
30
5 mm
but
d 1av Z 1 m av 30 5
150 mm
b 55.08
0.3672
d 1av 150
Step 7
d 1av N 1
v
60 1000
150 1200
9.42 m/s
60 1000
Step 8
From P.S.G Data book, Pg.No. 8.16
Step 9
[M t] M t kd k
4546.25 kg fcm
454625 Nmm
Step 10
R
i2 1 [M t] 1
b 2
R 0.56 b m t yv cos
Step 11
Calculation of surface compressive stress
3
i2 1
0.72
c E [M t]
R 0.5 b ib
3
0.72
1.542 1
1.7 10 5 454625
165.25 0.5 55.08 1.54 55.08
HERTZ METHOD
Given data:
Power 9 kW 9 10 3 W
Material used
Pinion-Gear C20
Select
E eq 2.15 10 6 kg f/c m2
E eq 2.15 10 5 N/mm 2
Design of Bevel,Worm and Cross Helical Gears 3.93
Step 3:
Assume life 10000 hrs
N 10000 60 200
N 12 10 7 cycles
1.4 kbl 1
[b]
n k
kbl 1
667.2 N/mm 2
6672 kg f/cm 2
n Factor of safety
n2
k 1.2
1.4 kbl 1
[b]
n k
1.4 1 6672
2 1.2
3892 kg f/c m2
Step 5:
Calculate design surface contact compressive stress [ c]
[ c] C B HB kcl kg f/cm 2
Where
C B 20
HB 170 to 200
Take HB 170
kcl 1
Design of Bevel,Worm and Cross Helical Gears 3.95
[c] 20 170 1
3400 kgf/cm 2
[ c] 340 N/mm 2
Where
97420 kW
Mt
N
Where
N S peed in rpm 200 rpm Given
kW n ominal power in kW 9 kW Given
97420 9
Mt
200
4383.9 kg f cm
[M t] M t kd k
4383.9 1.3
5699.07 kg f cm
3.96 Design of Transmission Systems
1 kgf cm 100 N mm
2
0.72 E [M t]
R y
i2 1
3
0.5 [ ] cm
i
y c
R
y From PSG Data book table 13 Pg no. 8.15
b
2 6
0.72 2.15 10 5699.07
32 1
3
R3 3 0.5 [3400]
3
7.1750 10 9 4.0843 10 9
3
R3 10
R3 10 3.08304
R 29.24 cm
R 30 cm
R 300 mm
R 0.5 mt Z 1
i2 1
Design of Bevel,Worm and Cross Helical Gears 3.97
Assume Z 1 20
R
mt
0.5 Z 1
i2 1
300
mt
0.5 20
32 1
300
mt
31.6227
m t 9.486 mm
Take m t 10 mm
b
Step 9: Calculate to find k
d 1av
To find d 1
av
b sin 1
mm m t
Z1
b 0.3 R
0.3 300
90 mm
Z 1 20
3.98 Design of Transmission Systems
5.73 20
114.6 mm
d1 N 1
av
v m/sec
60 1000
114.6 200
v
60 1000
v 1.2 m/sec
Calculate
b 90
ratio 0.785
d1 114.6
av
k 1.06
Select IS quality 10
Design of Bevel,Worm and Cross Helical Gears 3.99
[M t] M t kd k
kd 1.1
k 1.06
[M t] 5111.6274 kgf cm
[M t] 511162.74 N mm
R
i2 1 [ M t] 1
b [b]
R 0.5 b b m t yv c o s
2
Where
R Cone distance 30 cm
Pressure angle 20
i Speed ratio 3
b face width 9 c m
3.100 Design of Transmission Systems
m t transverse module 1 cm
yv form factor
Z1
Zv
cos 1
20
c o s 71.56
Z v 63.22
y v 0.490
R
i2 1 [M t]
1
b 2
R 0.5 b b m t yv cos
30 32 1
5111.6274 1
2
30 0.5 9 9 1 0.490 c o s 20
484931.554
2694.664
b 175.95 kg f c m [ b] 3892 kg f cm
c
0.72
R 0.5b
i2 13
ib
Eeq [M t] [c]
c
0.72
30 0.5 9
3 2 13
39
2.15 10 6 5111.6274
0.72
113453.25
25.5
3203.3 kgf c m
HERTZ METHOD
Solution:
Given data
P 15 kW 15 10 3 W
select
E eq 2.15 10 6 kgf/cm 2
E eq 2.15 10 5 N/mm 2
Step 3:
Life is not given in the question, so Assume life
N 10000 hrs
N 10000 60 1600
96 10 7 cycl es
1.4 kbl 1
[b]
n k
k bl 0.7
Design of Bevel,Worm and Cross Helical Gears 3.103
1 0.35 u 1200
Where
u 90
Take u 90 kg f/mm 2
9000 kg f/cm 2
4350 kg f/cm 2
n Factor of safety
n 2.0
k 1.2
3.104 Design of Transmission Systems
1.4 kbl 1
[b]
n k
C R 280
HRC 55
K c1 0.585
[ c] 280 55 0.585
9009 kgf/cm 2
[ c] 900.9 N/mm 2
Twisting moment [M t] M t k d k
Where
97420 kW
Mt
N
Where
N Speed in rpm 1600 rpm
kW Nominal power in kW 15 kW
97420 15
Mt
1600
M t 913.3125 kg f c m
k d k 1.3
[M t] m t kd k
[M t] 913.3125 1.3
[M t] 1187.306 kg f cm
[M t] 11873.06 N mn
2
0.72 E [M t]
R y
3
i2 1 0.5 [ ] cm
i
y c
R
y From PSG Data book, table 13 Pg no.8.15
b
Take y 3 (based on i 4)
2 6
0.72 2.15 10 11873.06
42 1
3
R3 3 0.5 9009 4
3
17 3
1.4193 10 9 6.3817 10 9
25.78 cm
R 26 cm
R 260 mm
R 0.5 mt Z 1
i2 1
Assume Z 1 20
R 260
mt
0.5 Z1
i 12
0.5 20
42 1
M t 6.38 mm
Design of Bevel,Worm and Cross Helical Gears 3.107
b
Step 9: Calculate to find k
d1
av
To find d 1
av
b sin 1
m m mt
Z1
b 0.3 R
0.3 260
b 78 mm
Z 1 20
tan 1 i
1 tan 1 4
1 75.96
78 sin 75.96
mm 8
20
m m 4.21 mm
d1 m m Z1
av
4.21 20
3.108 Design of Transmission Systems
84.2 mm
d1 N 1
av
v m/sec
60 1000
84.2 1600
v
60 1000
v 7.05 m/sec
Calculate
b 78
ratio 0.92
d1 84.2
av
b
k 1.1 Corresponding to 1.0
d1
av
[M t] M t kd k
913.3125 1.4 1.1
1406.50125 kg f cm
140650.10 N mm
where
R Cone distance 26 cm
Pressure angle 20
i Speed ratio 4
Mt Design torque 1406.50 kg f c m
b Face width 7.8 c m
Mt Transverse module 0.8 cm
yv Form factor
20
Zv
cos 75.96
Z v 82.44
y v 0.499
R i2 1
[ M t]
1
b 2
R 0.5b b mt yv cos
26
4 2 1 1406.50 1
2
26 0.5 7.8 7.8 0.8 0.499 c o s 20
150777.8496
1429.07
b 105.507 kg f/cm 2
c
0.72
R 0.5b
i2 13
ib
E eq [M t] [t]
0.72
26 0.5 7.8
42 13
4 7.8
2.15 10 6 1406.50125
0.72
82423.05 2685.27 kg f/cm 2
22.1
c 2685.27 kg f/cm 2 [ c] 9009 kg f/c m2
HERTZ METHOD
Solution
Step 1
Selection of material (From P.S.G. Data book,
Pg.No. 1.12)
Step 2
calculation of design stresses
C R 23; HRC 45
for life 25,000 hrs
N 25000 60 200
30 10 7 cycles
From P.S.G. Data book, Pg.No. 8.17
life factor for surface strength kcl 0.585
1.4 k bl
[b]pinion 1 (From P.S.G. Data book,
n k
Pg. No. 8.18)
1 0.25 u y 50
315 N/mm2
1.4 1 315
[b]pinion
2.5 1.5
117.6 N/mm2
we know that
30 10 7 30 10 7
N wheel 7.5 10 7 cycles
i 4
Design of Bevel,Worm and Cross Helical Gears 3.113
6 10 7
kcl
N wheel
6 10 7
0.714
7.5 10 7
1.4 k cl
[ b]wheel 1
n ka
1 0.45 u
0.45 300
135 N/mm 2
9 10 7
kbl
N wheel
9 10 7
0.799
7.5 10 7
n 2.5
k 1.2
1.4 0.799
[b]wheel 135 5.03 N/mm2
2.5 1.2
Step 3
Determination of R (Design of pinion)
2
0.72 E [Mt]
R y
2 3
i 1 0.5 [ ]
i
y c
i 4 given
[M t] k o k k d M t
k o 1 assumed
kW
M t 97420
N
3.5
97420
200
1704.85 kg fcm
Design of Bevel,Worm and Cross Helical Gears 3.115
170.48 Nm
[M t] 1 1.3 170.48
221.63 Nm
2 5 3
3 3 0.72 1.7 10 221.63 10
R
16 1 3 0.5 605.5
4
159.17 mm
Step 4
Determination of m t
R 0.5 m t
i2 1 Z1 (From P.S.G. Data book, Pg.
No. 8.38)
159.17 0.5 m t
16 1 18 assume Z1 18
mt 4.28 mm
Take m t 5 (standard)
Step 5
Recalculate R and find b
R 0.5 5 16 1 18
185.54 mm
R 185.54
b 61.8 mm
3 3
Step 6
Calculate m av , d 1av and pitch line velocity,
R 0.5 b
m av m t
R
185.54 0.5 61.8
5
185.54
4.17 mm
d1av Z 1 m av
18 4.17 75 mm
d 1av N 1
Pitch line velocity, v (from P.S.G. Data
60 1000
book, Pg. No. 8.15)
75 200
v 0.8 m/s
60 1000
Step 7
Revise k, kd and [M t]
b 61.8
Since 0.824
d1av 75
b
From P.S.G. Data book, Pg.No. 8.15, for 1
d1av
and surface hardness is less than 350 BHN for wheel
k 1.1
kd 1
[M t] 1 1.1 1 170.48
187.53 Nm
Design of Bevel,Worm and Cross Helical Gears 3.117
Step 8
Calculation of Induced stresses
0.7 R
i2 1
b [M t]
R 0.5 b2 b m t yv
tan 2 i 4
2 tan 1 4 76
Z1 18
Zv 19
cos 1 cos 14
where
we know that
Z 2 i Z 1 4 18 72
Z2
But Zv From P.S.G. Data book, Pg.No. 8.39
cos 2
72
297.6 ~
300
c o s 76
HERTZ METHOD
Solution
i 3, 25, Z1 15 teeth, P 8 HP 5.888 kW
740 N/mm2
1.4 kbl
[b] 1
n k
3.120 Design of Transmission Systems
But
1 0.25 u y 50 From PSG Data bookPg. No. 8.19
320 N/mm2
1.4 1 320
[ b ]
2.5 1.5
119.5 N/mm2
2
0.72 E [M t]
3
R y i2 1 0.5 [ ]
y c i
R
Assume y 3 (From P.S.G. Data book, Pg.No.
b
8.15)
i3
ko 1 assumed
k k d 1.3 assumed
5.888 10 3 60
Mt 102.229 Nm
2 550
2 5 3
0.72 2.1 10 132.89 10
3 2 3
R 3 1 3 0.5 [740]
3
106.355 mm
But R 0.5 m t Z 1
i2 1
106.355 0.5 m t 15
10
m t 4.48 5 mm standard
from P.S.G. Data book, Pg.No. 8.2
R 0.5 5 15
10
118.58 mm
R 118.58
b 39.528 mm
3 3
But
b sin 1
m av mt (From PSG Data book Pg.No. 8.38)
Z1
tan 2 i 3
2 tan 1 3 71.5
d1av N 1
v pitch lin e velocity m/s
60 1000
3.122 Design of Transmission Systems
62.45 550
v 1.79 m/s
60 1000
k 1.6 for b/d1av 0.64 from P.S.G. Data book, Pg.No. 8.15
k 1.4
228.99 10 3 Nmm
R
2
i 1 [M t]
b 2
from P.S.G. Data book, Pg.No. 8.13
R 0.5 b b mt yv
Z1 15
Z v Z eq 15.81 16
cos 1 cos 18.5
118.58
3 2 1 228.99 10 3
b
118.58 0.5 39.528 2 39.528 5 0.355
75 mm
Z2
i3
Z1
Z 2 3 15 45
d 2 Z 2 m t 25 mm
Gear forces
2 M t 2 102.229 10 3
Tangential force F t
d1av 62.4
3276.5 N
3.124 Design of Transmission Systems
1448.93 N
484.796 N
HERTZ METHOD
Given data
Power transmitted P 25 kW
pinion
Material used C45
gear
w.k.t
N1 300
i 1.5
N2 120
Solution:
1. Selection of Material
Refer PSG Data book Pg No.1.12
Design of Bevel,Worm and Cross Helical Gears 3.125
Given
C45, surface hardened to 45 RC and core hardness ~
350 BHN for pinion and wheel
Select
E eq 2.15 10 6 kg f/cm 2
E eq 2.15 10 5 N/mm 2
N 10000 60 300
18 10 7 cycles
1.4 kbl 1
[b]
nk
kbl 1
3.126 Design of Transmission Systems
1 733.2 N/mm 2
1 7332 kg f/cm 2
n factor of safety
n 2.0
k 1.2
1.4 kbl 1
[b]
n k
1.4 1 7332
2 1.2
C R 230
HR c 45
kcl 0.585
6054.75 kgf/cm 2
[ c] 605.47 N/mm2
Where
97420 kW
Mt
N
3.128 Design of Transmission Systems
where
N Speed in rpm 300 rpm.
kW Nominal power in kW 25 kW
97420 25
Mt
300
8118.33 kg f cm
k d k 1.3
[M t] M t kd k
[M t] 8118.33 1.3
[M t] 10553.829 kg f cm
[M t] 1055382.9 N mm
0.72 E [M t ]
i2 1
3
R y 0.5 [ ] cm
i
y c
R
y From PSG Data book table 13 Pg no 8.15
b
2 6
0.72 2.15 10 10553.829
R3
1.52 1
3
3 0.5 6054.75 1.5
R 5.408
34.2254
R 5.408 5.850
R 31.63
R 32 cm
R 320 mm
R 0.5 m t Z 1
i2 1
Assume Z 1 20
R
mt
0.5 Z 1
i2 1
320
mt
0.5 20
1.52 1
m t 17.75 mm
Take m t 18 mm
3.130 Design of Transmission Systems
b
Step 9: Calculate to find k
d1
av
To find d 1
av
b sin 1
mm m t
Z1
b 0.3 R
b 0.3 320
96 mm
Z 1 20
tan 1 i
1 tan 1 1.5
1 56.30
96 sin 56.30
m m 18
20
14.006 mm ~
14 mm
d1 mm Z1
av
14 20
280 mm
d1 N1
av
v m/s ec
60 1000
280 300
60 1000
v 4.398 m/sec
Calculate
b 96
ratio 0.342
d1 280
av
k1
Select IS quality 10
[M t] M t k d k
M t 10533.829 kg f cm
3.132 Design of Transmission Systems
k d 1.1
k1
[M t] 10533.839 1.1 1
[M t] 11587.2119 kg f cm
[M t] 1158721.19 N mm
R
i2 1 [M t]1
b 2
[b]
R 0.5b b m t yv cos
where
R Cone distance 32 cm
Pressure angle 20 (Assume).
i Speed ratio 1.5
[M t] Design torque 11587.2119 kgf cm
b Face width 9.6 cm
Mt transverse module = 1.8 cm
yv Form factor
20
c o s 56.30
36.04
Design of Bevel,Worm and Cross Helical Gears 3.133
y v 0.458
R
i2 1 [M t] 1
b 2
[ b]
R 0.5b b m t y v c o s
32
1.5 2 1 11587.2119 1
2
32 0.59.6 9.6 1.8 0.458 cos 20
668452.5863 1
5855.271 c o s 20
b 121.48
c
0.72
R 0.5b
i2 1 3
ib
Eeq [M t] [ c]
c
0.72
32 0.5 9.6
1.52 13
1.5 9.6
2.15 10 6 11587.2119
3.134 Design of Transmission Systems
0.72
100679.2518
27.2
c 2665.039 kg f c m
HERTZ METHOD
Given Data:
Power P 7.5 kW
Z2
i 3
Pinion speed N 1 1440 rpm Z1
Gear ratio i 3
Step 1
Selection of Material: From PSG Data book P.No.
8.16; table (16) Material Given C45
HRC 40 to 55
Assume HRC 50
Design of Bevel,Worm and Cross Helical Gears 3.135
Step 2
Life of gears. (N)
N 10,000 hrs
Life
N 86.4 10 7 Cycles
of Gears
Step 3
Equivalent Young’s modules ‘E’
E 2.15 10 5 N mm2
Step 4
kbl 1
3150 kg f c m2
n 2.5
k 1.5
1176 kg f cm 2
[b] 117.6 N mm 2
Design of Bevel,Worm and Cross Helical Gears 3.137
Step 5
HRC 50 assumed
HRC 50
7
k Cl From PSG Data book P.No.8.17; P.No.17 steel, N 25 10
kcl 0.585
[ c] 672.75 N mm2
Step 6
kW
M t 97420
N1
3.138 Design of Transmission Systems
7.5
97420
1440
507.39 kg fcm
[M t] 507.39 1.3
659.61 kg fcm
Step 7
2
0.72 E[M t]
R y
i2 1 0.5 [ ] i
y c
R
y
b
Assume y 3 (for i 1 to 4)
i Gear ratio 3
[c] 672.75 N mm 2
E 2.15 10 5 N mm 2
[M t] 659.61 100 N mm
Design of Bevel,Worm and Cross Helical Gears 3.139
2 5
0.72 2.15 10 659.61 100
3 2 1
3
R3 3 0.5 672.75
3
R 90.43 mm
Step 8
R 0.5 mt Z 1 i2 1
assume Z 1 20 teeth
mt 2.859 mm
Step 8 (a):
Recalculate (R) and Calculate (b)
R 0.5 m t Z 1
i2 1
0.5 3 20
3 2 1
R
y 3
b
3.140 Design of Transmission Systems
R 94.86
b 31.62 mm
3 3
Step 9
To find k ; Calculate b d1 av
To find d 1 ;
av
(or) 18.43
d1 Z 1 m av R 0.5 b
av d1 m tZ 1
av
R
20 2.5 50 mm 94.86 0.5 31.62
3 20
94.86
b 31.62 50 mm
0.06324
d 1av 50
Step 10
Selection of IS Quality
Design of Bevel,Worm and Cross Helical Gears 3.141
50 1440
v
60 1000
v 3.769 m/sec
Step 11
Step 12
[ M t ] M t kd k
1136.55 kg fcm
[ M t ] 113655 Nmm
Step 13
R
i2 1 [ M t ] 1
b 2
[ b ]
R 0.5b b m tyv cos
R
i2 1 [ M t ] 1
b 2
[ b ]
R 0.5b b m t y v c o s
94.86 32 1 113655 1
2
94.86 0.5 31.62 31.62 3 0.3955 cos 20
Trail 2
Assume transverse module m t 4 mm
Step 8 (a)
R 0.5m t Z 1
i2 1
0.54 20
32 1
R 126.49 mm
R 126.49
b 42.16 mm
3 3
Step 9
sin 1
m av m t b
Z1 1 18.43
sin 18.43
4 42.16
20
m a v 3.33 mm
d1 Z1 mav
av
20 3.33 66.67 mm
b 42.16
y
d1 66.67
av
0.6323
k 1.6
3.144 Design of Transmission Systems
Step 10
d1 N1
av
v
60 1000
66.67 1440
60 1000
5.026 m/sec
Step 11
kd 1.4
Step 12
[ M t ] Mt k d k (Similar to previous step)
1136.55 kg fcm
[ M t ] 113655 Nmm
y v 0.3955
(Similar to previous step)
Step 13
R
i2 1 [ M t ] 1
b 2
R 0.5b b m t yv c o s
126.49 3 2 1 113655 1
2
126.49 0.5 42.16 42.16 4 0.3955 c o s 20
Step 14
Calculation of induced surface contact compressive
stress c; ( Notes use only recalculated values)
c
0.72
R 0.5b
i2 13
ib
E[ M t ] [ c ]
R 126.49 mm ; b 42.16 m m ; i 3
3
2 3
0.72 1
c 2.15 105 113655
126.49 0.5 42.16 3 42.16
To Find Angles
From PSG Data book P.No. 8.39 Table (31)
[f o 1 ]
1. Addendum angle a
m t fo
tan a tan a
1 2 R
3.146 Design of Transmission Systems
41
a a tan 1
1 2
126.49
a a 1.81
1 2
2. Dedendum angle f
m t fo c
f f tan 1
1 2 R
4 1 0.2
tan 1
126.49
f f 2.17
1 2
3. Tip angle a 1 a
1 1
(Pinion)
18.43 1.81
a 20.24
1
4. Root angle f 1 f
1 1
(Pinion)
18.43 2.17
f 16.26
1
420 2 c o s 18.43
da 87.58 mm
1
420 2 c o s 71.57
Design of Bevel,Worm and Cross Helical Gears 3.147
da 82.52 mm
2
4 20
d1 80 mm
4 60
d2 240 mm
Given Data:
P 12 kW
Angle between
70
two shafts
Pressure
20
angle
Face width b 40 mm
N1 360
i 3;
N 2 120
Assume Z 1 20 teeth
Z 2 No. of teeth
i Z 1 Z 1 no.of teeth on pinion
on Gear
Z 2 3 20 60 teeth
d1 m t Z1
d1 200
mt 10 mm
Z1 20 (which is equal to standard module)
0.5 10 20
3 2 1
R 316.22 mm
sin
tan 1
i cos
Design of Bevel,Worm and Cross Helical Gears 3.149
sin 70
tan 1
3 cos 70
1 tan 1 0.2811
1 15.7
2 70 15.7
2 54.3.
Addendum Angle: a
m t f0
tan a
1 R
m t f0
Addendum angle of pinion a tan 1
1
R
10 1
tan 1
316.22
a 1 48 a
1 2
m t f0
Dedudum angle of pinion f tan 1
1
R
10 1
tan 1
316.22
f 210 f
1 2
1542 1 48
a 566
2
Root angle
f 1 f
of pinion 1 1
1542 210
1332
Root angle
f 2 f
of pinion 2 2
5418 210
528
12
97420 kg fcm 3247.33 kg fcm
360
Torque M t 324733 N mm
2 324733
F tav 3466.58 Newton
40
200 1 0.5
316.22
Ftav 3.466 kN
Design of Bevel,Worm and Cross Helical Gears 3.151
1.2016 kN
Fa 0.3413 kN
M 2 F t overhang
Re sultan t BM
M21 M22
113.7 2 415.92 2 431.18 kNmm
E quivalent
Torq ue on Te
M2 T 2 [T Mt 324733 N mm]
shaft
Te
431.18 10 32 3247332 539785.75 N mm
Te d3 539785.75 N mm
16 S
LW
Pa
l a n
D W D OW
x DT
D OG
DG
Rf Rr
b
l Pa Z1 Pc Z1
d2 d1 d1
. .
. P a P c
Design of Bevel,Worm and Cross Helical Gears 3.155
m x Z1
tan
d1
mx Z 1
d1
Z2
i gear ratio
Z1
m x axial m odule
d 1 Pitch circle diameter of worm
d 2 pitch circle diameter of worm wheel
d1
q diam eter factor
mx
a centre distance
Z1
lead angle tan 1
q
4. Tooth Pressure Angle: It is measured in a plane
containing the axis of the worm and equal to one half the
thread profile angle.
Z1 Z2
Pd
d 1 sin d2 sin PN
Note:
The reciprocal of the normal diametrical pitch is
known as Normal Module m n
1 d1 sin d2 sin P N
mn
Pd Z1 Z2
90
90
N1 Z2
i
N2 Z1 . . N1 Z2
.
N2 Z1
Design of Bevel,Worm and Cross Helical Gears 3.157
tan
1 2
tan
tan Friction Angle
F s m x b [ b] y
F s m x b [ b ] Y Y
y
where
mx – Axial module
b – Face width
[b] – Allowable Static Stress
y – Form factor for worm wheel
3.158 Design of Transmission Systems
Where,
Ft – Tangential load
Fd – Dynamic load
vmg – Pitch line velocity of worm gear
F w d2 b kw
d2 – Pitch diameter of worm wheel
b – Face width
kw – Wear Factor (or) load stress factor
H g P 1
P – Power in watts
– Efficiency of worm gearing
H d A T2 T1 K
Where
H d Heat dissipated
Hg Hd
P 1 A T2 T1 K
W orm W orm
W orm G ea r G ea r
G ea r
S h aft
+
FR
FR
FA
FT
W orm
W orm S h aft W orm
2 Tw
FT
d1
where,
Tw – Torque on worm.
d1 – Pitch circle diameter of worm.
Gear ratio i Z2
i
Z1
Diameter factor q d1
q
mx
Axial pitch Px Px mx
Addendum modification x a
x 0.5 q Z2
coefficient mx
pressure angle
friction angle
Step 1:
For a given problem note down the given parameters
like Power, gear ratio (i), speed, etc.
d1
11
mx [If q is not given Assume q 11 ]
m x axial module
3.164 Design of Transmission Systems
Z1
Lead Angle tan 1
q
To determine Z 1 (no. of starts of gear); It is based on
the efficiency of worm gear drive. choose the appropriate
value From PSG data book pg. 8.46, Table 37.
Step 4:
Calculation of Tangential load Ft acting on the wheel in
terms of axial module mx
HP 75
Tangential load F t
vmg
vmg pitch line velocity of worm gear
d2 N2 d 2 in mm
vmg
60 1000 N 2 rpm
Power in HP
Step 5:
Calculation of Dynamic Load Fd
6 vmg
Fd Ft
6
Step 6:
Calculation of strength of gear tooth
[b] y bP cn [ b ] y b
Fs
P dn P cn Normal circular pitch
P dn Normal Diametrical pitch
[b] yb mx
[b] Y b mx
Design of Bevel,Worm and Cross Helical Gears 3.165
Step 7:
Determine the m x
Step 8:
b~
8.25 m x [From Data book Pg. 8.48, Table: 38]
Step 9:
Step 10:
Step 11:
Step 12:
Step 13:
Checking for beam strength
F d F s for safe design.
Step 14:
Calculation of wear load Fw
F w d2 b kw
Step 15:
Checking for wear strength
F d F w For safe design.
Step 16:
Checking for efficiency
actual design then the design is safe.
tan
actual
tan
[From PSG Data book pg no. 8.49]
co-efficient of friction.
Step 17:
Calculation the power loss (or) Heat Generated
H g 1 a Input hp 4500 kg f m/min
(Or)
a actual
Design of Bevel,Worm and Cross Helical Gears 3.167
Step 18:
Calculate the area required to dissipate the heat
Heat generated Heat dissipated to the atmosphere
(Or)
substitute A in m 2, K in W/m 2
H d A T 2 T 1 K
H d in watts.
Step 19:
Calculate the basic dimensions of worm and worm wheel.
From the PSG Data book pg 8.43 table 35.
Step 20:
Draw the neat sketch of worm and worm wheel.
Problem 3.13 A hardened steel worm rotates at 1440 rpm
and transmits 12 kW to a phosphor bronze gear. The speed of
the worm wheel should be 60 3% rpm. Design the worm gear
drive if an efficiency of atleast 82% in desired, and also
determine the heat generated, required area of cooling to
dissipate the generates heat. Temperature rise restricted to
40C and heat transfer co-efficient 10 W/m2C
3.168 Design of Transmission Systems
Solution:
Step 1:
Given Data
desired 82%
Step 2:
Selection of Material
Worm - Hardened Steel
Worm Wheel - Phosphor bronze
Step 3:
Calculation of lead Angle
d1
Diameter factor q
mx
d1
11 d1 11 mx
mx [Assume q 11
If not given]
tan 1 Z/q
Z1
tan 1
11
Design of Bevel,Worm and Cross Helical Gears 3.169
tan 1 3 /11
15.25
Step 4:
N1
i
N2
1440
3% i
60
Z2
i 24 0.72 ; i ~
24 i
Z1
m x 72 60 Z 2 24 3
vmg 0.226 m x
60 1000 Z 2 72
3
12 10
P hp
750
P 16 hp
hp 75
Ft kg f
vmg
16 75
0.226 m x
3.170 Design of Transmission Systems
5309.73 53097.3
kg f N
mx mx
Step 5:
Calculation of Dynamic Load Fd
6 vmg
Fd Ft
6 (Assume vmg 5 m/s)
6 5 53097.3
N
6 mx
97345.05
N
mx
Step 6:
Calculation of strength of gear tooth Fs Y y
F s [b] y m x [ b] b Y m x
From PSG Data book pg. 8.45, Table 33. (For bronze,
rotation in only one direction)
0.75 11m x
8.25 m x
F s 78 8.25 m x 0.392 mx
F s 252.252 m 2x
Design of Bevel,Worm and Cross Helical Gears 3.171
Step 7:
Fs Fd
97345.05
252.252 m 2x
mx
m 3x 385.903
m x 7.28
mx ~
8 mm
From the PSG Data book pg. no.8.2, Table 1 (Choose the
largest standard module from table).
Step 8:
8.25 8
b 66 mm
Step 9:
72 8
576 mm
3.172 Design of Transmission Systems
Step 10:
Pitch line velocity of worm wheel V2
V 2 0.226 m x
V 2 1.808 m/min
Step 11:
Recalculation of Dynamic Load Fd
97345.05
Fd N
mx
F d 12168.13125 N
Step 12:
Recalculation of Strength of Gear Tooth Fs
F s 252.252 m 2x
16144.128 N
Step 13:
Checking for Beam Strength Fs
F s F d for satis factory design
16144.128 12168.14
Fd FS
Step 14:
Calculation of wear load Fw
Fw d2 b kw
d 2 576 mm
Design of Bevel,Worm and Cross Helical Gears 3.173
b 66 mm
Fw d2 b kw
576 66 0.56
F w 21288.96 N
Step 15:
Fw Fd
F w 21288. 96 N ; Fd 12168.14
Step 16:
Checking for efficiency
tan
actual
tan
tan 1
1.718
15.25
tan
actual
tan
tan 15.25
tan 15.25 1.718
0.27262
0.30512
0.8934 100
desired 82%
actual 89.34%
89.3% 82%
7675.2 kg f/min
Step 18:
hcr 10 W/m2C
Nm
10
Sm 2C
Nm
6 kgfm/min
S
10 kgfm 60
60 10 m 2C min
7675.2 kgf/min h cr t A 1 w/m 2C 6 kg fm/minC
hcr 60 kgfm/min C
kg f m
7675.2 kg fm/min 60 A 40
min C m n
A 3.198 m2
Step 19:
151.84
L~
152 mm
a 0.5 m x q Z 2x
332 mm (Assume x 0)
7. Height Factor fo 1
8. Bottom Clearance
c 0.2 m x to 0.3 m x [Take c 0.3 m x]
c 0.3 8
2.4 mm
9. Pitch Diameter
d1 mx q 2x
mx q
8 11
88 mm
d 2 Z 2m x
72 8
576 mm
10. Tip diameters da
d a1 d1 2fom x
88 2 1 8 104 mm
d a2 Z 2 2f0 2n m x n 0
72 2 1 0 8
592 mm
df d 1 2fom x 2C
1
88 2 1 8 2 2.4
67.2 ~
68 mm
df Z 2 2fo m x 2C
2
72 2 1 8 2 2.4
555.2 ~
56 mm
Solution:
Step 1:
Given Data
Power P 12 kW 12 10 3 W
To Find
Heating capacity of gears H g
Efficiency ( actual)
3.178 Design of Transmission Systems
Step 2:
Selection of Material
Worm - Hardened steel
Step 3:
d 1 11 m x
Z1
tan 1
q (Assume Z 1 3
if not given).
1
tan 3/11
15.25
Step 4:
12 10 3
Power P hp
750
16 hp
Design of Bevel,Worm and Cross Helical Gears 3.179
d2 N2 d2 m x Z2
vmg
60 1000 Z2
i
90 mx 40 Z1
60 1000 Z 2 30 3
0.18849 m x Z 2 90
hp 75 d2 90 m x
Ft
vmg
N1
30
16 75 N2
0.18849 m x 1200
N2
30
6366.385 653663.85
Ft kgf N N 2 40 rpm
mx mn
Step 5:
Calculation of Dynamic Load Fd
6 vmg
Fd Ft
6 (Assume vmg 5 m/s
6 5 63663.85
6 mx
116717.05
Fd
mx
Step 6:
Calculation of strength of gear tooth Fs
F s [ b] b Y m x
F s 78 8.25 m x 0.92 m x
F s 252.252 m 2x
Step 7:
Calculation of axial module mx
For safe design
Fs Fd
116717.05
252.252 m 2x
mx
116717.05
m 3x
252.252
462.700
m x 7.73
m x~
8 mm
Step 8:
Calculation of face width (b)
b 8.25 m x
8.25 8
b 66 mm
Step 9:
Calculation of pitch circle diameter d 2
d2 Z2 m x
90 8
d 2 720 mm
Step 10:
Pitch line velocity of worm wheel V2
V 2 0.18849 m x
0.18849 8 60
90.5 m/min
Step 11:
Recalculation of dynamic load Fd
116717.05 116717.05
Fd
mx 8
F d 14589.63 N
Step 12:
Recalculation of strength of gear tooth Fs
F s 252.252 m 2x
16144.128 N
3.182 Design of Transmission Systems
Step 13:
Checking for Beam Strength
For satisfactory design,
Fs Fd
16144.128 14589.63
Step 14:
Calculation of Wear Load (Fw
F w d2 b kw
d2 720 mm ; b 66
Fw d2 b kw
720 66 0.56
26611.2 N
Step 15:
Checking for Wear strength
For satisfactory design
Fw Fd
26611.2 F w 14589.63 F d
Step 16:
tan
Efficiency actual
tan
15.25
tan 15.25
actual
tan 15.25 1.718
89.35%
Step 17:
Heating capacity of great (H g ) (or) power loss (or)
Heat generated.
H g 1 a Inpu t hp 4500 kg f m/min
H g 1278 Watts . . 1 Nm
. W
s
Step 18:
Calculate the basic dimensions of worm and worm
wheel.
1. Axial module m x 8 mm
3.184 Design of Transmission Systems
164.8
L~
165 mm
404 mm
c 0.3 m x
[Take c 0.3 m x]
0.3 8
2.4 mm
88 2 8 2 1 2.4 67.2
68 mm
df2 Z 2 2fo m x 2c
df2 ~
700 mm
Solution:
Step 1:
Given Data
Power P 22.5 kW 22.5 10 3 W
Step 2:
Selection of Material
Worm Always Select (steel)
Worm wheel Choose bronze
From PSG Data book Pg No.8.45; Table 32.
Step 3:
Calculation of lead angle
d1
Diameter Factor q
mx (Take q 11 )
d 1 11 m x
Z1
tan 1
q Z 1 3 0.8 0.9
d 0.8
tan 1 3/11
15.25
Step 4:
Calculation of tangential load Ft
hp 75 Z2
Ft i
vmg Z1
d 2 N2 N1
vmg i
60 1000 N2
m x72 60 [d 2 72 m x] 1440
i
60 1000 60
i 24
0.226 mx m/s Z 2 24 3
Z 2 72
Design of Bevel,Worm and Cross Helical Gears 3.187
22.5 10 3
Power P hp
750
30 hp
hp 75
Ft kgf
V mg
30 75 9955.75
kg f
0.226 m x mx
99557.5
Ft N
mx
Step 5:
Calculation of Dynamic Load F d
6 vmg
Fd Ft
6 Assume vmg 5 m/s
6 5 99557.5
m
6 x
182522.08
Fd
mx
Step 6:
Calculation of strength of gear tooth F s
F s [ b] b Y m x
b 0.75 d 1
[b] 80 N/mm 2 for bronze.
8.25 mx
3.188 Design of Transmission Systems
F s 80 8.25 m x 0.392 m x
258.72 m 2x
Step 7:
Calculation of axial module m x
For safe design
F s Fd
182522.08
258.72 m 2x
mx
m 3x 705.481
m x 8.90
mx ~
10 mm
Step 8:
Calculation of face width b
b 8.25 m x
8.25 10 82.5 ~
83 mm
Step 9:
Calculation of pitch circle diameter d 2
d2 Z2 m x
72 10
d2 720 mm
Design of Bevel,Worm and Cross Helical Gears 3.189
Step 10:
Pitch line velocity of worm wheel V2
v2 vmg 0.226 m x
0.226 10
2.26 m/s
Step 11:
Recalculation of Dynamic Load Fd
182522.08 182522.08
Fd
mx 10
F d 18252.208 N
Step 12:
Recalculation of strength of great tooth Fs
F s 258.72 m 2x
258.72 10 2
F s 25872 N
Step 13:
Check for Beam Strength
F s F d For satisfactory design.
F s 25872 18252.208 F d
Step 14:
Calculation of Wear Load Fw
F w d 2 b kw
3.190 Design of Transmission Systems
d 2 720 mm ; b 83 mm
F w 720 83 0.56
33465.6 N
Step 15:
F w 33465.6
F d 182522.08 N
Step 16:
tan 1 0.03
1.718
15.25
Design of Bevel,Worm and Cross Helical Gears 3.191
tan 15.25
actual
tan 15.25 1.718 desided 80%
actual 0.8934
actual 89.34%
The actual efficiency is greater than that of desired
efficiency, The design is safe [a d]
Step 17:
Calculate the basic dimensions of worm and worm
wheel.
1. Axial module m x 10 mm
2. Number of starts Z 1 3
4. Face width b 83 mm
5. Length of Worm L 12.5 0.09Z 2 mx
L 12.5 0.09 72 10
189.2
~
190 mm
7. Height Factor fo 1
9. Pitch diameter
d1 m x q 2n d 2 Z 2m x
d1 10 11 0 72 10
110 mm 720 mm
(Assume n 0 )
10. Tip diameter d a
df2 Z2 2fo mx 2c
df1 d 1 2fom x 2c
72 2 10 2 3
99 2 10 2 3
694
df1 73 mm
d f2 694 mm
Worm: Steel
Step 2
Step 3
Z2 i Z1
Step 4
d1
q d 1 pitch diameter of Worm in mm
mx
m x axial module - mm
Initially assume q 11
Step 5
2
Z2 3 540 [M t]
a 1 Z 10 cm
q 2
q [c]
(Or)
2
Z2 1 3 540 [M t]
a Z 10 cm
q 2
q [c]
Substitute c in N/mm 2
2a
mx
q Z 2 2x
assume x 0
x addendum modification coefficient
Refer data book, Refer PSG Data book Page No.
8.2, take the standard value of module.
m x q Z 2
a
2
V1 Z1
Sliding velocity vs tan
cos q
where lead angle
Check vs: Z1
tan 1
q
If vs 3 m sec, then reduce surface stress by 30% of
[ c] design initial value.
d 2 N 2 d2 mxZ
v2 m sec
60 N 2 wheel speed in rpm
for v2 3 m sec
kd 1;
540 Z 2/q 1
C [M t] [C ] in kgf/c m
Z2 q a
Design of Bevel,Worm and Cross Helical Gears 3.197
(Or)
3
Z2
1 [m t ]
540 q
c in N/mn2
Z2 a 10
q
Substitute a in mm; [M t] in N-mm; then get c in
N/mm 2
tan Where
tan lead angle in degree
friction angle in degree
Refer PSG Data book Pg
NO.8.49
3.198 Design of Transmission Systems
From Graph,
at sliding velocity and
according to material
take the value of
where frictional
coefficient
But tan
Step 13:
(Assume x 0
2. Number of starts Z 1
7. Height factor fo 1
Given data
P 22.5 kW ; N 1440 rpm ; i 24 ; T o T a T 40C ;
85%
Solution
Step 1: Selection of material
Assuming worm material as steel and wheel material
as Bronze (sand cast)
number of starts Z 1 3
3.200 Design of Transmission Systems
Z2
since i
Z1
Z2 i Z 1 24 3 72
d1
Assume q diameter factor 11 (initially)
mx
Assume intially k k d 1
hp
M t 71620 i
n
2 N
P Mt
60
P 60 22.5 103 60
Mt 3581 N m
2 N2 1440
2
24
From PSG Data book Pg.No. 8.44
2
Z2 3 540 [M t]
a 1 Z 10
q 2
q [ c ]
2
72 3 540 3581 10 3
1 345.9
11 72 10
11 159
a~
346 mm
2a
Axial module m x
q Z 2 2x
Assume x 0
2a 2 346
mx
q Z 2 11 72
m x 8.4 mm
axial module m x 10 mm
d 1 11 10 110 mm
Step 5:
From PSG Data book Pg.No. 8.44
V1
Sliding velocity vs
cos
Z1 1 3
But tan 1 tan 11
q
15.25
and
d 1 N1 110 1440
v1
60 1000 60 1000
v1 8.3 m/s
8.3
vs
cos 15.25
vs 8.6 m/s
[ c] 0.8 159
127 N/mm 2
3
Z2
1 [M t]
540 q
c
Z2 a 10
q
3
72
1 3
540 11 3581 10
72 /11 415 10
1.9 [M t]
b
m 3x qZ 2 yv
Z2 72
Zv 3
3
80
cos cos 15.25
Z v 80
y v 0.499
1.9 3581 10 3
b 3
17.22 N/mm2 [b]
10 11 72 0.499
Step 8: Efficiency
From PSG Data book Pg.No. 8.49
3.204 Design of Transmission Systems
tan
tan
0.03
tan
1.718
tan 15.25
tan 15.25 1.718
0.8935 89.35%
[Assume kt 10 w /m 2 C ]
A 5.99 m 2
Solution
P 2 kW
N 1 720 rpm
d 1 50 mm
Z 2 40 teeth
m 5 mm
Z2 40
i V.R 10
Z1 4
Step 1
Selection of material
Worm – steel
Wheel – Bronze, sand, chill
[b] 50 N/mm2
Step 2
Calculation of centre distance
2
Z2 3 540 [M t]
a 1 Z 10
q 2
q [ ]
c
3.206 Design of Transmission Systems
Initially assume k kd 1
Po wer 60 2 10 3 60
Mt
2 rpm of wh eel 720
2
10
265.25 Nm
265.25 10 3 Nmm
[M t] M t k k d
265.25 10 3 1
265.25 10 3 Nmm
2
40 3 540 265.25 10 3
a 1
10 40 10
10 159
133.7 mm
Step 3
Lead angle
Z1
tan
q
4
0.4
10
tan 0.4
Design of Bevel,Worm and Cross Helical Gears 3.207
tan 1 0.4
21.8
Step 4
Efficiency of worm gearing
tan
tan
v1
We know sliding velocity vs
cos
d1 N 1
But v1
60 1000
50 720
v1 1.884 m/s
60 1000
1.884
vs 2.03 m/s
cos 21.8
0.045
But tan
tan 0.045
tan 1 0.045
2.576
3.208 Design of Transmission Systems
tan 21.8
tan 21.8 2.576
0.8827
88.27%
Step 5
Power lost in friction Q
Q P 1
2 103 1 0.8827
234.6 watts
0.234 kW
Solution
Given Data:
2M t kW
Ft M t 97420
d2 N1
2 730.65 15
97420
6.5 2000
224.81 kg 730.65 kg f cm
F a F t tan Z1
tan
q
224.81 tan 15.47 5.71 d2 65
q 10.83
mx 6
87.10 kg 3
tan 1
10.83
Lead angle 15.47
3. Separating force
tan 15.47
0.7142
tan 15.47 5.71
71.42%
3.210 Design of Transmission Systems
Solution
Given Data:
Gear
speed of worm 1440
ratio i 36 2%
speed of worm wheel 40
i.e , % deviation of i 2%
Selection of material and design stresses refer
Databook, Refer PSG Data book Page No. 8.45
Worm - steel;
Z2
But, i gear ratio ; where Z 2 no. of teeth on
Z1
worm wheel
Z 2 iZ 1 36 2 72 teeth
d
Assume q diameter factor 11 (initially)
mx
m x axial module mm
Design
torque [M t] M t kd k
25464.88 1 1 hp
M t 71620 i
[M t] 25464.88 kgfcm n
20
71620 32 0.8
1440
25464.88 kg f c m
Assume k kd 1 initially
2
Z2 3 540
a 1 Z q [ ] [M t]
q 2 C
3.212 Design of Transmission Systems
2
72 3 540
a 1 25464.88
11 72 1590
11
a 30.88 cm 388.8 mm
axial module m x 10 mm
m x q Z 2 10 11 72
a 415 mm
2 2
110 mm
3
540 Z 2 q 1
C [Mt] [ c]
Z 2 q a
72
540
11 1
25464.88
72 11 415
32.276 kg f cm 2 [ c] 1113 kg f cm 2
D rive r D rive r
D rive r D rive r
L eft-H an d
D rive r D rive r
1 2 or 2 1
G ea r 1
(R igh t-H a nd (L eft-H a nd )
2
1 2
1
G ea r 2
(R igh t-H a nd )
P d Diameteral pitch
P dn P cn
P cn P c cos 1 P c cos 2
1 2
P d1 Pd 2
P dn
cos 1 c o s 2
Z 1 P cn
D 1 pitch diameter of driving wheel
c o s 1
Similarly,
Z 2 P cn
D 2 pitch diameter of driven wheel
c o s 2
Z2 D 2 cos 2
i velocity ratio
Z1 D 1 cos 1
Z1 Z2
cos 3 1 cos3 2
b face width – cm
Y form factor y
C wear and lubrication factor
[b] b Y
FS kgf
P dn C w
Modified as,
Fd Ft Cv
where hp 75
F t Transmitted load
Vm
hp is the given power
V m is the mean velocity in m/sec
Design of Bevel,Worm and Cross Helical Gears 3.219
4.5 V m
Velocity factor C v
4.5
F w kQ D 21
Example
No. Item Symbol Formula
Pinion Gear
1 Normal module ma 3
2 Normal Pressure n 20
Angle
3 Helix Angle 20 30
4 Number of Teeth Z1, Z2 15 R 24 L
& Helical Hand
5 Number of Teeth zv Z 18.0773 36.9504
3
of an Equivalent cos
Spur Gear
6 Radial Pressure 1 tan n 21.1728 22.7959
tan 1
Angle cos
( D rive r)
H ig h
H ig h Sp eed
Sp eed
(D rive r)
L ow
L ow S peed
Sp eed
( D rive n)
( D rive n)
(b) Bevel G ear
(a) Sp ur Gear
L ow speed
D riven
L
L ow
Sp eed
D riven
H ig h
Sp eed
D river
H ig h S peed D river (c) Worm & Worm Wh eel
Fig. 4.1 Single Red uction Sp eed R edu cers
4.6 Design of Transmission Systems
H S pur G ears
W orm
W he el
I I
I I
L I
L
L H
W orm
(a) Spur Gears (b) Spu r An d (c) W orm & Wo rm Wh eel
H - H igh Spe ed Bevel G ears and Spu r G ear
I - In term ed iate S pe ed
L - L ow S pe e d Fig. 4.2 Do uble R eduction Speed Reducers
Step 1
N max
Z 1
N min
1st Method
The standard step ratio values are available in
(Refer PSG databook, Page No. 7.20) R5 – 1.6; R10 – 1.25;
R20 – 1.12; R40 – 1.06. The standard step ratio values are
given in Geometric progression in the above series.
For example
N max
Z 1
Nmin
355
12 1 ; 1.12
100
2nd Method
For example
N max
Z 1
N min
1600
6 1; 1.26
500
Trail 1
Take R40 series step ratio 1.06 and try multiples.
1.06
1.06 1.06 1.06 1.26
Skip 3 speeds.
By multiplying R40 series step ratio by 4 times, the
value obtained is similar to the required step ratio.
Therefore take R40 series by skipping three speeds
N 6 1600
3rd Method
If the value is not coinciding with standard step
ratio. (or) If the multiples of standard step ratio are also
not coinciding, then find the speeds by using this method.
Note
Before using this method, first try method (1) and
method (2).
For example:
N max
Z 1
N min
600
12 1 1.345
23
Trail 1
Take R20 series multiples 1.12
Trail 2
Take 1.06 (R40 series) multiples
Skip 4 speeds.
Table 4.1
6 speeds 3 2 or 2 3
P1 P 2 P1 P2
9 speeds 3 3
P1 P 2
12 speeds 3 2 2 or 2 3 2 or 2 2 3
P1 P 2 P 3 P1 P2 P3 P1 P2 P3
18 speeds 3 3 2 or 2 3 3 or 3 2 3
P1 P 2 P 3 P1 P2 P3 P1 P2 P3
16 speeds 2 2 2 2
P1 P 2 P 3 P 4
Structural formula
Z P 1 X 1 , P 2 X 2 , P 3 X 3
1 st stage 2 nd stage 3rd stage
Speed Space
3 2 2 P1 3 X 1 1 always
P1 P2 P3
P2 2 X2 P1 3
P3 2 X3 P1 P2 3 2 6
N max Nmin 1
2 and (or)
N input N input 4
N max N input
N input N min
Table 4.2
No. of Approximate
Factors
speeds No. of gears
2 2 1 2 2 4
3 3 1 2 3 6
do not consider 1
4 22 2 2 2 8
6 23 2 2 3 10
8 222 2 2 2 2 12
9 33 2 3 3 12
12 232 2 2 3 2 14
16 2222 2 2 2 2 2 16
18 332 2 3 3 2 16
4.14 Design of Transmission Systems
Solution:
1.122
Structural Formula
u No. of stages 3
D raw u 1 3 1 4 vertical
lines.
Since 12 speeds, draw 12 horizontal
lines.
Join CA and CB
4.18 Design of Transmission Systems
N max
2
Ninput
Join H and F
FC 1 and FD 1
180 rpm 250 rpm
(Maintain again 3 space intervals in II stage)
C1A 1 and C 1B 1
112 rpm 224 rpm (Maintain again 6 space
intervals in III stage)
Join H and G
From (G) draw 2 speeds (200 rpm and 280 rpm)
GC 2 and GD 2
200 rpm 280 rpm (Maintain again 3 space
intervals in II stage)
From C2 draw 2 speeds (125 rpm and 250 rpm)
C2A 2 and C 2B 2
125 rpm 250 rpm (Maintain again 6 space
intervals in III stage)
From D:
DA3 and DB 3
140 rpm 280 rpm (Maintain again 6 space
intervals in III stage)
From D1:
D1A4 and D 1B 4
160 rpm 315 rpm (6 space intervals)
From D2:
D2A5 and D 2B 5
180 rpm 355 rpm (6 space intervals)
Kinematic Diagram
No. of Gears required are
23 2 2 27
14 Gears For details, refer
page 4.13. Table 4.2
Calculation of Number of Teeth: Refer kinematic
arrangement
III Stage
Speed of driven N 1 Z 2
Speed of driver N2 Z1 Speed of driver N 160 rpm
2
Speed of driven N1 100 rpm
Let Z 2 20 teeth
(Assume above 17 teeth.)
100 20 1st Pair: Z1 32 teeth
160 Z 1
Z2 20 teeth
20 160
Z1 32 teeth
100
2nd Pair: Increasing speed N 3 driven speed 200 rpm
N 4 driver speed 160 rpm
Speed of driven N 3 Z 4
Speed of driver N 4 Z 3 ... (1)
32 20 Z 3 Z 4
Z3 Z4 52 ... (2)
4.22 Design of Transmission Systems
200 Z 4
Z 4 1.25 Z 3
160 Z 3
Z 3 1.25 Z3 52
52
Z3 23
2.25
Take Z3 23 teeth
2nd Pair Z3 23 teeth
Z 4 52 23 29 teeth Z4 29 teeth
II Stage
1st Pair: Reducing speed
Speed of driven N 7 Z8
Speed of driver N 8 Z 7
N8 driver speed 200 rpm
160 20
N7 driven speed 160 rpm
200 Z 7 Assume Z 8 20 teeth
20 200
Z7 ; Z 7 25 teeth
160
Speed of driven N 5 Z 6
Speed of driver N 6 Z 5
25 20 Z 5 Z 6
Z5 Z6 45 ... (1)
Design of Speed Reducers (Gear Boxes) 4.25
224 Z 6
200 Z 5
Z 6 Z 5 1.12
Z 5 1.12Z 5 45
45
Z5 21.22
2.12
Take Z 5 21 teeth
2nd Pair: Z5 21 teeth
Z 6 45 21 Z6 24 teeth
24 teeth
I Stage
In this stage, there are 3 speeds; and 3 pairs of gears
are required.
To avoid interference of gear of one shaft with the
gear of the other shaft while shifting,
Z 1 Z 3 9 4 also Z7 Z5 4
Z 4 Z 2 9 4; Z 6 Z8 4; condition satisfied
1st Pair: Reducing speed N 10 driver speed 355 rpm
N 9 driven speed 200 rpm
Speed of driven N9 Z 10
Speed of driver N 10 Z9 Assume Z 10 20 teeth
200 20
355 Z 9
355 20
Z9 35.5
200
Take Z9 36 teeth
4.26 Design of Transmission Systems
Z10 20 teeth
Spee d of driven N 13 Z 14
Speed of driver N 14 Z 13
224 Z 14
355 Z13
Z 9 Z 10 Z 13 Z 14 36 20 56
Z 13 0.63Z 13 56
56
Z 13 34 teeth
1.63
Z 13 34 teeth
Z 14 56 34
22 teeth
Speed of driven N 11 Z 12
Speed of driver N 12 Z 11
250 Z 12
355 Z 11
Z 11 Z12 56
Z 11 0.704 Z 11 56
Z 11 32.85
T ake Z 11 33 teeth
3rd Pair: Z11 33 teeth
Z12 23 teeth
Z 12 56 33 23 teeth
1st stage
Z 5 21 teeth Z 1 32 teeth
Z 6 24 teeth Z 2 20 teeth
Z 7 25 teeth Z 3 23 teeth
Z 8 20 teeth Z 4 29 teeth
Given Data:
No. of speeds Z 6
N max
Z 1
N min
1600
6 1
500
1
5
1600
1.2619
500
1.2619 is not a standard step ratio.
1.06
Structural Formula
Z32 P1 3 X1 1
P1 P2
P2 2 X 2 P1 3
st
Z P 1X 1, P 2X2 In 1 stage
3 represents - No. of speeds
1 represents - space between speeds
3 1, 2 3 In the 2nd stage,
st nd
1 Stage 2 Stage 2 represents - No. of speeds
3 represents space between speeds
Ray Diagram:
No. of stages 2; so 3 vertical lines
Nmax Nmin 1
Either 2 or
Nip Nip 4
1000
1.25 2
800
Join DB 1 parallel to CB
2nd Stage
1st pair Z 1 and Z 2 - Reducing speed
4.32 Design of Transmission Systems
Design of Speed Reducers (Gear Boxes) 4.33
4
*
3
*
1
2
10
*
9
*
7
8
*
5
6
4.34 Design of Transmission Systems
Z2 N1
Z1 N2
Z2 800
20 500
Z 2 32 teeth
Z1 20 teeth
Z2 32 teeth
Z 1 Z 2 Z 3 Z 4 20 32 52
Z 3 Z 4 52 ... (1)
No. of teeth on driven Speed of driver
No. of teeth on driver Speed of driven
Z4 800
0.8
Z3 1000
Z 3 0.8Z 3 52
52
Z3 28.88
1.8
Z 3 29 teeth
But Z 3 Z 4 52
N14 driver speed 355 rpm
23 teeth
Z3 29 teeth
Z4 23 teeth
1st Stage
Z6 N5
Z5 N6
1600
Z 6 20 40
800
Z5 20 teeth
Z6 40 teeth
Z 5 Z 6 Z 7 Z 8 60
Z 7 Z 8 60
... (3)
Z8 N7
Z7 N8
Design of Speed Reducers (Gear Boxes) 4.37
1600
Z8 Z
1250 7
Z 7 1.28 Z7 60
60
Z7 26.31
2.28
Take Z7 27 teeth
But Z 7 Z 8 60
Z 8 60 27 33 teeth
Z7 27 teeth
Z8 33 teeth
Z 5 Z 6 Z7 Z8 Z 9 Z 10 60
Z 9 Z 10 60 ... (5)
Z 10 N9 1600
But, Z 10 Z
Z9 N 10 1000 9
4.38 Design of Transmission Systems
1.6 Z 9
... (6)
Substitute the value of Z 10 in eq. (5)
Z 9 1.6 Z 9 60
60
Z9 23.07
2.6
Take Z 9 23 teeth
Z 10 60 23 37 teeth
Z9 23 teeth
Z10 37 teeth
II Stage I Stage
Z 1 20 Z 5 20
Z 2 32 Z 6 40
Z 3 29 Z 7 27
Z 4 23 Z 8 33
Z 9 23
Z 10 37
Check
To avoid interference
Z 7 Z 5 and Z 7 Z9 4
27 20 7 and 27 23 4
Design of Speed Reducers (Gear Boxes) 4.39
Given Data:
No. of speeds Z 9
Max. speed N max 900 rpm
Min. speed N min 56 rpm
Input speed 720 rpm
N max
Z 1
N min
900
9 1
56
1
900 8
56
1.415
Trail 1
C2
N 9 = 9 00 rp m
In pu t (N ) =7 20 rp m
C1
N 8 = 6 30 rp m
N 7 = 4 50 rp m
F C
N 6 = 3 15 rp m
E B2
N 5 = 2 24 rp m
D B1
N 4 = 1 60 rp m
B
N 3 = 112 rpm
A2
N 2 = 8 0 rpm
A1
N 1 = 5 6 rpm
3 (3) A
3 (1)
Ray D iagram fo r Nine S peed Gear Box
Design of Speed Reducers (Gear Boxes) 4.41
2
1
3
4
5
6
8
7
10
9
11
12
4.42 Design of Transmission Systems
Structural Formula
Z33 P1 3 X1 1
P1 P2
P2 3 X2 P1 3
st
Z P 1X 1, P 2X2 In 1 stage,
3 represents No. of speeds
1 represents space between speeds
31, 33 In 2nd stage,
st nd
1 Stage 2 Stage 3 represents no of speeds
3 represents space between speeds
Ray Diagram
Mark N 1 to N 9 in Ray diagram.
N max N min 1
Select input speed 2 and
N i p N ip 4
450 56
Select N ip 224 rpm 2 0.25
224 224
II Stage
Z2 N1
Z1 N2
224
Z 2 20 80
56
Z1 20 teeth
Z2 80 teeth
Z4 N3
Z3 N4
224
0.4977
450
Z 1 Z 2 Z3 Z 4 20 80 100
Z 3 Z 4 100
Z 3 0.4977 Z 3 100
100
Z3
1.4977
66.76
Take Z 3 67 teeth
Z 4 100 67 33 teeth
Z3 67 teeth
Z4 33 teeth
Z6 N5 224
Z5 N6 160
Z6
1.4 Z 6 1.4Z 5 3
Z5
Z 5 Z 6 100 4
Z 1 Z 2 Z 3 Z 4 Z 5 Z 6 20 80 100
Z 5 1.4Z 5 100
100
Z5 41.66
2.4
Take Z 5 42 teeth
Z 6 100 42 58 teeth
Z5 42 teeth
Z6 58 teeth
Z 2 80 teeth Z 3 Z1
and 4
Z 3 67 teeth
Z 3 Z5
Z 4 33 teeth
Design of Speed Reducers (Gear Boxes) 4.47
Z 5 42 teeth 67 20 47
4
67 42 25
Z 6 58 teeth
There is no interference.
1st Stage
Z8 N7
Z7 N8
720
Z 8 20 64.28
224
Z 8 65 teeth
Z7 20 teeth
Z8 65 teeth
4.48 Design of Transmission Systems
Z 9 Z 10 85 ... (5)
Z 10 N9 720
But, 1.6
Z9 N 10 450
Z 11 Z 12 85 ... (7)
Z 12 N 11 720
But, 2.285
Z 11 N 12 315
Z 12 85 26 59 teeth
Z11 26 teeth
Z12 59 teeth
1st Stage
Z 7 20 teeth Similarly,
Z 8 65 teeth Z 7, Z 9, Z11 are driver gears.
Z 9 32 teeth
Z 10 52 teeth Check for interferen ce,
Z 11 26 teeth Z9 Z7
4
Z 9 Z 11
Z 12 59 teeth
32 20 12
4 Since both
32 26 6
are greater than four.
There is no interference.
4.50 Design of Transmission Systems
Solution:
N max
Z 1
N min
N max 650 rpm
650
18 1
35 N min 35 rp m
1
17
650 Z 18
Step ratio
35
1.1875
Trail 1
R40 series
1.06
1.06
1.06 1.06 skip 2 speeds
1.191
Structural formula,
332
P1 P2 P3
P2 3 X 2 P1 3
P3 2 X 3 P1 P 2 3 3 9
I In pu t
N 1 8 = 67 0
N 1 7 = 56 0
N 1 6 = 47 5
N 1 5 = 40 0
N 1 4 = 33 5
E
N 1 3 = 28 0
H
N 1 2 = 23 6
G
N 11 = 200
F
B
D N 1 0 = 17 0
N 9 = 1 40
N 8 = 118
N 7 = 1 00
C
N6 = 85
N5 = 71
N4 = 60
N3 = 50
N 2 = 4 2.5
N 1 = 3 5.5
1 st Sta ge . 3 (1) 2 nd S tage . 3 (3) 3 rd Sta ge . 2 (9) A
*
*
*
13
15 11
I Stage 16 12
14
II S tage
*
*
*
Z 3 =4 9
D riven 5
9 7
6 Z1 = 20 D river
10 (100 rpm )
8
*
*
D riven
Z 8 = 25
Z 10 = 32
Z 1 4 =10 4 (280 rpm ) Z 6 = 40
Z 16 =1 08 (170 rpm )
(2 80 rpm )
Z 1 2 = 114 (100 rp m)
(236 rpm ) (236 rpm )
D rive n
Z 4 = 28
Z 2 = 57
Kinem atic Arrangement of 18 Speed Gear Bo x. (170 rpm )
(35.5 rpm )
Design of Speed Reducers (Gear Boxes) 4.53
4.54 Design of Transmission Systems
N max 100
280 0.5 0.25
1.4 2 200
Ni p 200
Z2 N1
Speed ratio
Z1 N2
100
Z 2 20 56.3
35.5 Z1 20 teeth
4.56 Design of Transmission Systems
Z 1 Z 2 Z 3 Z4 57 20
Z 3 Z 4 77 ... (1)
Z4 N3
But, speed ratio
Z3 N4
Z4 100
0.5882
Z3 170
Z 3 0.5882 Z 3 77
77
Z3 48.48
1.5882
Take Z 3 49 teeth
Z 4 77 49 28
Z3 49 teeth
Z4 28 teeth
Design of Speed Reducers (Gear Boxes) 4.57
For II Stage
3 speeds - 3 pairs of gears.
1st Pair - Z 5 and Z 6 - Reducing speed
Z6 N5 200
Speed ratio 2
Z5 N6 100
Z 6 20 2 40 teeth
Z5 20 teeth
Z6 40 teeth
Z 7 Z 8 60 ... (3)
4.58 Design of Transmission Systems
Z8 N7 200
But, speed ratio 0.7142
Z7 N8 280
Z 7 0.7142 Z 7 60
60
Z7 35.001
1.7142
Take Z 7 35 teeth
Z 8 60 35 25
Z7 35 teeth
Z8 25 teeth
Z 9 Z 10 60 ... (5)
Z 10 N9 200
Speed ratio, 1.176
Z9 N 10 170
Z 9 1.176 Z9 60
60
Z9 27.57
2.176
Take, Z 9 28 teeth
Z 10 60 28 32 teeth
Z9 28 teeth
Z10 32 teeth
To avoid interference,
Z 5, Z 7 and Z 9 are driver gears with Z 5 20 teeth
Z 7 35 teeth and
Z 9 28 teeth
Condition
Z7 Z5 4 35 20 15
I Stage
In first stage, the No. of speeds required are 3.
Therefore, six gears are required.
Z 12 N 11 670
Speed ratio
Z 11 N 12 200
670
Z 12 17 56.95 57 teeth
200
Take Z12 57 teeth
Z 13 Z 14 74 ... (7)
Z 14 N13 670
But, speed ratio
Z 13 N 14 280
Z 13 2.3928Z 13 74
74
Z 13 21.81
3.3928
Take Z 13 22 teeth
and Z 14 74 22 52 teeth
Z13 22 teeth
Z14 52 teeth
Z 15 Z 16 Z 11 Z 12 Z 13 Z 14 74
Z 15 Z 16 74 ... (9)
Z 16 N15 670
But, speed ratio
Z 15 N 16 236
Z 15 2.8389Z 15 74
4.62 Design of Transmission Systems
74
Z 15 19.27
3.8389
Take Z 15 20 teeth
Z 16 74 20 54 teeth
Z15 20 teeth
Z16 54 teeth
To Avoid Interference
Z 13 Z 11 4; i.e., 22 17 5
and Z 13 Z 15 4; i.e.,22 20 2
Z 11 17 2 34 teeth
Z 12 57 2 114 teeth
Z 13 22 2 44 teeth
Z 14 52 2 104 teeth
Z 15 20 2 40 teeth
Z 16 54 2 108 teeth
Check again,
Design of Speed Reducers (Gear Boxes) 4.63
Z 13 Z 11 44 34 10
Z 13 Z 15 44 40 4
3rd Stage
Z 1 20 teeth
Z 2 57 teeth
Z 3 49 teeth
Z 4 28 teeth
2nd Stage
1st Stage
Z 5 20 teeth
Z 11 34 teeth
Z 6 40 teeth
Z 12 104 teeth
Z 7 35 teeth
Z 13 44 teeth
Z 8 25 teeth Z 14 104 teeth
Z 9 28 teeth Z 15 40 teeth
Given Data
N min 280 rpm ; N max 1800 rpm ;
P ower 5.5 kW; Z 9 speed
Solution
We know that
N max
Z 1
N min
1800
9 1
280
1.26
Structural formula
Z33 ; P1 3 ; X1 1
9 P 1, P 2 ; P2 3 ; X2 P1 3
P1 X 1, P 2 X 2
9 3 1, 3 3
Since number of stages u 2 ,
Draw u 1 2 1 3 vertic al lines
Sinc e 9 speeds, draw 9 ho rizo ntal lines
Design of Speed Reducers (Gear Boxes) 4.65
N max 1120
1.57 2
N input 710
N m ax 280 1
0.39
N input 710 4
Z 12 710
Z12 50.71 ~
52 teeth
20 280
II stage II pair
Z7 N8 560
Since 0.788
Z8 N7 710
4.66 Design of Transmission Systems
also Z 7 0.788 Z8
Since
Z 7 Z 8 Z 11 Z12
0.788 Z 8 Z 8 20 52 Z8 40 teeth
Z7 32 teeth
and Z9 44 teeth
I stage, I pair
Assume Z5 20 teeth
Z5 N6 710
Since 0.507 Z6 40 teeth
Z6 N5 1400
I stage II pair
Z1 N1 900
Since 0.64 Z1 0.64 Z 2
Z2 N2 1400
also Z 1 Z 2 Z 5 Z6
0.64 Z 2 Z 2 20 40 ; Z2 37 teeth
and Z1 24 teeth
Design of Speed Reducers (Gear Boxes) 4.69
But Z 3 Z 4 Z 5 Z6
0.8 Z 4 Z 4 20 40
Z4 34 teeth
a nd Z3 28 teeth
Solution
N max 600 rpm, Nmin 100 rpm; P 3 kW ; Z 9,
N input 1440 rpm
We know that
N max
Z 1
N min
600
9 1
100
8 6 6 1/8
1.25
Structural formula
Z33
9 P 1, P 2
P 1 X 1, P 2 X2
P 1 3, X 1 1
P 2 3, X 2 3
9 3 1, 3 3
u no . o f stages 2
N max
2
N input
400
1.6 2
250
N min 1
and 0.25
N input 4
100
0.4 0.25
250
Kinematic diagram:
No. of gears required 2 3 3 12
II stage
Let
Driven
Z 2 No of teeth on driven
Z2 N1
Z1 N2
N1
Z2 Z1
N2
250
20
100
Z 2 50
Z1 20 teeth, Z 2 50 teeth
Z4 N3
Z3 N4
N3
Z4 Z3
N4
Design of Speed Reducers (Gear Boxes) 4.75
250
Z4 Z 0.625 Z 3
400 3
Z 4 0.625 Z3
Z1 Z2 Z3 Z4
Z 3 Z 4 20 50 70
Z 3 Z 4 70
Z 3 0.625 Z 3 70
Z3 43.07 44 teeth
and Z4 26 teeth
Z6 N5 250
Z5 N6 200
Z 6 1.25 Z 5
Z 1 Z 2 Z3 Z 4 Z 5 Z 6 20 50 70
Z 5 Z 6 70
Z 5 1.25 Z 5 70
Z5 31.11 32 teeth
Z 6 70 32
Z 6 38 teeth
4.76 Design of Transmission Systems
II stage
Z 1 20 teeth; Z 4 26 teeth
Z 2 50 teeth; Z 5 32 teeth
Z 3 44 teeth; Z 6 38 teeth
To check interference:
Z 1, Z 3, Z 5 are driver
Z3 Z1
a nd 4
Z Z
3 5
44 20
and 4
44 32
There is no interference
I stage
1st pair
Z8 N7
Z7 N8
600
Z8 20 48 teeth
250
Z7 20 teeth
Z8 48 teeth
2nd pair
Z 9 Z 10 68 teeth
But
Z10 N9
Z9 N 10
600
Z 10 Z 9 1.5 Z 9
400
Z10 1.5 Z 9
Z 9 1.5 Z9 68
Z9 27.2 28 teeth
3rd pair
Z7 Z 8 Z 9 Z 10 Z 11 Z 12 68
Z 11 Z 12 68
But
Z12 N 11 600
Z 11 N 12 315
Z 12 1.9 Z 11
Z 11 1.9 Z 11 68
Checking of interference
Z9 Z7
and 4
Z Z
9 11
28 20
28 24 4
There is no interference
Design of Speed Reducers (Gear Boxes) 4.79
Given Data
No. of speeds Z 9
Solution
We know
N max
Z 1
N min
1000
8 1.22
200
Trail 1
Take R40 series multiples 1.06
1.26
not satisfactory
4.80 Design of Transmission Systems
N 1 200 rpm
Structural formula
Z33
P1 3 ; P2 3
and X1 1 ; X 2 P 1 3
Z P 1 X 1, P 2 X 2
3 1, 3 3
Ray diagram
N max N min
Select input speed; 2 and 4
N input Ninput
9 speed 3 3 2 3 3 12 gears
Calculation of No. of teeth on gear
Let Z1 No. of teeth on driver 20 teeth Assume
We know that
Z2 N1
Z1 N2
N1 444
Z2 Z 1 20 45 teeth
N2 200
Z1 20 teeth, Z2 45 teeth
Z4 N3
Similarly,
Z3 N4
444
Z4 Z 3
662
Z4 0.671 Z 3
G 1400 rpm
986 rpm
C2
808 rpm
C1
662 rpm
F C
B2
542 rpm
E
B1
D
444 rpm
364 rpm
B
A2
298 rpm
A1
244 rpm
200 rpm
3(1) 3(3) A
Ray D iag ram
Design of Speed Reducers (Gear Boxes) 4.83
D riven
D riven
4.84 Design of Transmission Systems
Z 1 Z 2 Z3 Z 4
Z 3 Z 4 20 45
Z 3 Z 4 65
Z 3 0.671 Z 3 65
Z3 39 teeth
and Z4 26 teeth
Similarly,
Z6 N5 444
Z5 N6 364
Z6 Z 5 1.2197
Z 1 Z 2 Z 3 Z4 Z 5 Z6 20 45 65
Z 5 Z 6 65
Z 5 1.2197 Z 5 65
Z5 30 teeth
and
Z 6 65 30 35
Z6 35 teeth
Z 1, Z 3, Z 5 are driver
Design of Speed Reducers (Gear Boxes) 4.85
Z3 Z1
and 4
Z3 Z5
39 20
39 30 4
There is no interference
Similarly,
Z8 N7
Z7 N8
N7 1400
Z8 Z7 20
N8 444
64 teeth
Z7 20 teeth, Z8 64 teeth
Z 7 Z 8 Z9 Z 10 20 64 84
Z 9 Z 10 84 ... (1)
But
Z 10 N9 1400
2.11
Z9 N 10 662
4.86 Design of Transmission Systems
Z9 27 teeth
Z 7 Z 8 Z 9 Z10 Z 11 Z 12 85
Z 11 Z 12 85
Z 12 N 11 1400
But, 2.583
Z 11 N 12 542
Z 12 2.583 Z 11
Z 11 2.583 Z 11 84
Z11 23 teeth
Check of interference
Z9 Z7
4
Z9
Z 11
27 20
27 23 4
Satisfactory, there is no interference
Given Data
No. of speeds Z 9
P 5 kW
Solution
N max
Z 1
N min
1500
Z 1 1.40
100
Trial 1:
Consider R20 series, which is having step ratio 1.12
N 1 100 rpm
N 2 N 1 140 rpm
N 3 N 2 196 rpm
N 4 N 3 274 rpm
N 5 N 4 384 rpm
N 6 N 5 538 rpm
N 7 N 6 753.2 rpm
N 8 N 7 1054 rpm
N 9 N 8 1476 ~
1500 rpm
Structural formula
Z 3 3 ; P1 3 ; X1 1
P2 3 ; X2 P1 3
Z P 1 X 1, P 2 X 2
3 1, 3 3
where,
753
1.96 2
384
N min 100
0.26 0.25
N i/p 384
N inp ut 384
For I stage
No. of speeds required are 3
For II stage
No. of speeds required are 3
II stage
N1 Z2
N2 Z1
Assume Z 1 20 teeth
384
Z2 20 78 teeth
100
Z1 20, Z2 78 teeth
4.90 Design of Transmission Systems
1 44 0 rpm
1 50 0 rpm
1 0 5 4 rpm
7 53 rp m
F C
5 38 rp m
E
3 84 rp m
D
2 74 rp m
B
1 96 rp m
1 40 rp m
1 00 rp m
3 (1) 3 (3) A
Ray D iag ram
Design of Speed Reducers (Gear Boxes) 4.91
2
1
3
4
5
6
10
9
11
12
4.92 Design of Transmission Systems
Z3 Z4 Z1 Z2
Z 3 Z 4 98
N3 Z4 384
N4 Z3 753
N3
0.509
N4
Z4 0.509 Z 3
Z3 0.509 Z 3 98
Z3 65 teeth
Z4 33 teeths
Z5 N6
Z6 N5
274 Z 5
Z 5 0.7135 Z6
384 Z 6
Also
Z 5 Z 6 Z3 Z4
Z 5 Z 6 98
0.7135 Z 6 Z 6 98 Z6 58 teeth
and Z5 40 teeth
To check interference
Z 1, Z3, Z 5 are driver
Design of Speed Reducers (Gear Boxes) 4.93
Z3 Z1
and 4
Z Z
3 5
there is no interferenc e
I stage
N8 Speed of driver shaft 1440 rpm
Z7 N8
Z8 N7
Assume Z7 20 teeths
N7 1440
Z 8 20 20 75 teeth
N8 384
and
Z7 20, Z8 75 teeth
Z9 Z 10 Z 7 Z 8 Z 9 Z 10 95 teeth
and
Z9 N 10 N 10
Z 9 Z10
Z 10 N9 N9
753
Z 10 0.5229 Z 10
1440
0.5229 Z 10 Z10 95
Z10 63 teeth
and
4.94 Design of Transmission Systems
Z9 32 teeth
Z 11 N12 Z 11 538
Z 11 0.3736 Z 12
Z 12 N 11 Z12 1440
and
Z 11 Z 12 Z 9 Z 10
Z 11 Z 12 95
95
Z12 70 teeth
1.3736
Z11 95 70 25
Z9 Z7
4
Z 9 Z 11
There is no interference
Given data
Z 12 ; Nmin 100 rpm ; Nmax 1200 rpm ; P 5 kW
Solution
Nmax
Since Z 1
N min
Design of Speed Reducers (Gear Boxes) 4.95
1
1200 11
100
1.25
Structural formula
Z322 P1 3 X1 1
12 P 1, P 2, P 3 P2 2 X2 P 1 3
P1 X 1, P 2 X 2, P 3 X 3 P3 2 X3 P1 P2 3 2 6
STAGE 3
STAG E 2
STAG E 1
4.98 Design of Transmission Systems
N min 100 1
Sinc e 0.4
N input 250 4
N max 400
and 1.6 2
N input 250
Also Z 11 Z 12 70
1.6 Z 12 Z 12 70
Z12 27 teeth
II stage, I pair
Z7 N8 500
Since Z7 1.25 Z 8
Z8 N7 400
also Z 7 Z 8 Z9 Z10 52
Design of Speed Reducers (Gear Boxes) 4.99
1.25 Z 8 Z 8 52
Z8 24 teeth and Z7 28 teeth
Assume Z9 20 teeth
N9 400
Z 10 Z 9 20 Z10 32 teeth
N 10 250
Z6 50 teeth
I stage, II pair
Z3 N4 500
Since 0.5
Z4 N3 1000
Z3 0.5 Z 4
Also Z 3 Z 4 Z 5 Z6 70
Z 1 Z 2 70
Z1 N2 630
0.63
Z2 N1 1000
Z 1 0.63 Z2
0.63 Z 2 Z2 70
Z 2 43
Z 1 70.43 27
Z1 27 teeth
Z2 43 teeth
Solution
Z 12, N max 600 rpm, N min 25 rpm , P 2.25 kW ,
We know that
N max
Z 1
N min
600
12 1
25
1.334
N 1 25 rpm
Structural formula
Z322
12 P 1, P 2, P 3
P 1 X1, P 2 X 2, P 3 X 3
P 1 3; X 1 1
P 2 2; X 2 3 P 1
4.102 Design of Transmission Systems
P 3 2; X 3 P 1 P 2 6
N max N min 1
2 or or 0.25
N input N input 4
148 25
1.78 2 and 0.30 0.25
83 83
198 83
1.3 2 and 0.56 0.25
148 148
Kinematic diagram
No. of gears required 2 3 2 2 2 7
14 gears
III stage
Let Z 2 20 teeth
25 20
Z 1 66.4 67 teeth
83 Z 1
4.104 Design of Transmission Systems
Design of Speed Reducers (Gear Boxes) 4.105
Z1 67 teeth; Z2 20 teeth
But
N3 Z4
N4 Z3
and
Z1 Z2 Z3 Z4
Z 3 Z 4 67 20
Z 3 Z 4 87
and
148
Z4 Z3
83
Z 4 1.78 Z3
Z 3 1.78 Z 3 87
Z3 31.29 32 teeth
and Z4 55 teeth
II stage
1st pair: Reducing speed
But
Design of Speed Reducers (Gear Boxes) 4.107
N7 Z8
N8 Z7
Z 8 N8 148
Z7 Z8
N7 83
Z 7 1.783 Z 8
Assume Z8 20 teeth
Z7 35.66 36 teeth
But
N5 Z6
N6 Z5
and
Z7 Z8 Z5 Z6
36 20 Z 5 Z 6
Z 5 Z 6 56 teeth
and
198
Z6 Z5
148
Z 6 1.33 Z5
Z 5 1.33 Z 5 56
Z5 24 teeth
4.108 Design of Transmission Systems
Z6 31.92 32 teeth
I stage
In this stage, there are 3 speeds, and 3 pairs of gears
are required.
Z 12 Z 10 4 and Z 12 Z 14 4
N9 Z 10
But
N 10 Z9
148 20
600 Z 9
Z9 81.08 82 teeth
Let
But
Design of Speed Reducers (Gear Boxes) 4.109
N 13 Z 14
N 14 Z 13
198 Z 14
600 Z 13
Z 14 0.33 Z 13
and
Z 9 Z 10 Z13 Z 14
Z 13 Z 14 82 20
Z 13 Z 14 102
Z 13 0.33 Z 13 102
and
Z14 25 teeth
But
N 11 Z 12
N 12 N 11
265 Z 12
600 Z 11
Z 12 0.44 Z 11
4.110 Design of Transmission Systems
But
Z 11 Z12 Z 13 Z14
Z 11 Z 12 77 25
Z 11 Z 12 102
Hence
Z 11 0.44 Z 11 102
Z11 71 teeth
and
Z12 31 teeth
Z 12 Z 10 31 20 4
Z 12 Z 14 31 25 4
Solution
Given
P 5 kW, N max 355 rpm, Nmin 100 rpm
Z 12
Design of Speed Reducers (Gear Boxes) 4.111
N max
Z 1
N m in
355
12 1
100
1.122
Structural formula
Z322
12 P 1, P 2, P 3
P 1 X1, P2 X2, P 3 X 3
P 1 3; P 2 2; P3 2
X1 1 1
X 2 P1 3
X 3 P1 P2
326
4.112 Design of Transmission Systems
H 360
335
315
280
250
G
D
224
F
200
E B
180
160
C
140
125
112
100
I Stage II Stage III Stage A
3(1) 2(3) 2(6)
8
6
7
5
Driven
u No. of stages 3
N max
2 select N input 160
N input
200
or 1.25 which is less than 2
160
N min 1
or 0.25
N input 4
N max
2
N inp ut
224
1.12 w hich is less than 2
220
N min
1/4;
N input
160
0.8 Selection of N input 200 is satisfactory.
200
C 1 A 1 and C 1 B 1
Join H, G
From G draw 2 speeds (200 rpm and 280 rpm)
G C 2 and C D 2
C 2 A 2 and C 2 B 2
Kinematic Diagram
No. of Gears required are 2 3 2 2 2 7
14 Gears
III stage
speed of driven N 1 Z2
spe ed of driver N 2 Z1
let Z 2 20 teeth
100 20
160 21
20 160
Z1 32 teeth
100
Design of Speed Reducers (Gear Boxes) 4.117
Z2 32 teeth
speed of driven N 3 Z4
speed of driver N 4 Z3 ... (1)
Z1 Z2 Z3 Z4
20 32 Z 3 Z 4
Z 3 Z 4 52 ... (2)
200 Z 4
160 Z 3
Z 4 1.25 Z3
Z 3 1.25 Z 3 52
52
Z3 23
2.25
Take Z3 23 teeth
Z4 52 23 29 teeth
Z4 29 teeth
4.118 Design of Transmission Systems
II stage
1st pair: Reducing speed
speed of driven N 7 Z8
speed of driver N 8 Z7
160 20
200 Z7
20 200
Z7
160
Z7 25 teeth
Assume Z8 20 teeth
Z8 20 teeth
speed of driven N 5 Z6
speed of driver N 6 Z5
Z7 Z8 Z5 Z6
25 20 Z 5 Z 6
Z 5 Z 6 45 ... (1)
Design of Speed Reducers (Gear Boxes) 4.119
224 Z 6
200 Z 5
Z 6 Z 5 1.12
Z 5 1.127 5 45
45
Z5 21.22
2.12
Take Z 5 21 teeth
Z 6 45 21
24 teeth
Z6 24 teeth
I stage
In this stage there are 3 speeds; and 3 pairs of gears
are required. To avoid interference of gear of one shaft
with the gear of the other shaft while shifting:
Z 12 Z 10 4
Z 12 Z 14 4
N9 Z 10
; Assume Z 10 20
N 10 Z9
4.120 Design of Transmission Systems
Z 9 35.5 36 teeth
N 13 Z14 224
Z14 Z 13 0.63 Z13
N 14 Z 13 355
But Z 9 Z 10 Z 13 Z 14
56
Z 13 Z 14 36 20 56 Z 13 34 teeth
1.63
Z13 34 teeth
Z14 22 teeth
N 11 Z 12 250 Z 12
N 12 Z 11 355 Z 11
Z 12 Z 11 0.704
Z 11 Z 12 Z 13 Z 14 56
Z12 23 teeth
Multiply by 4
Satisfactory
Similarly
Solution
N max
Z 1
Nmin
2000
12 1
180
1.244
Not satisfactory
4.122 Design of Transmission Systems
N 1 180 rpm
N 2 N 1 224 rpm
N 4 N 3 347 rpm
N 6 N 5 536 rpm
N 7 N 6 667 rpm
N 8 N 7 830 rpm
N 9 N 8 1033 rpm
N 10 N 9 1285 rpm
N 11 N 10 1599 rpm
Z322
12 P 1, P 2, P 3
P 1 3; X 1 1
P 2 2; X 2 P 2 3
P 3 2; X 3 P 1 P 2 3 2 6
3rd stage
Locate N input
Design of Speed Reducers (Gear Boxes) 4.123
N max
2
Ninput
667
2
432
N min 1
N input 4
180 1
432 4
2nd stage
Mark N max 830 rpm as (B)
N max 836
1.25 2
N input 667
N min 432 1
0.647
N input 667 4
I stage
1st pair
Let Z2 20 teeth
4.124 Design of Transmission Systems
N 12 = 1 9 9 0 rp m
N 11 = 1 5 9 9 rp m
H
1440
rp m
N 10 = 1 2 8 5 rp m
N 9 = 1 0 3 3 rp m
N 8 = 8 3 0 rp m
D
N 7 = 6 6 7 rp m
E
B
N 6 = 5 3 6 rp m
N 5 = 4 3 2 rp m
C
N 4 = 3 4 7 rp m
N 3 = 2 7 9 rp m
N 2 = 2 2 4 rp m
N 1 = 1 8 0 rp m
I S ta g e 3 (1 ) II S ta g e 2 (3 ) III S ta g e 2 (6 ) A
Driver 1440 rp m
Z 6 = 28
Z 8 = 20
Z 4 =41
Z 2 =2 0
Z 5 = 23
(830 rpm ) Z 7 =3 1
(432 rpm )
Driven
Z 3 =27 Z 1 =48
Kinem atic D iagram (6 67rpm ) (18 0 rpm )
Design of Speed Reducers (Gear Boxes) 4.125
4.126 Design of Transmission Systems
N1 Z2
Since
N2 Z1
N2 432
Z1 Z 2 Z 1 20 48 teeth
N1 180
N3 Z4
Similarly
N4 Z3
and
Z 1 Z 2 Z 3 Z4
Z 3 Z 4 68 teeth
N3
Z4 Z3 Z 4 1.54 Z3
N4
Z 3 1.54 Z 3 68
Z 3 27 teeth
and
Z 4 68 27 41
Z 4 41 teeth
II stage
N7 Z8
N8 Z7
Take Z8 20 teeth
N8
Z7 Z8 Z7 31 teeth
N7
Design of Speed Reducers (Gear Boxes) 4.127
and
Z6 N5
Z5 N6
Z7 Z8 Z5 Z6
Z 5 Z 6 51 teeth
and
N5
Z6 Z5 Z 6 1.24 Z 5
N6
1.24 Z 5 Z 5 51
Z 5 23 teeth
and
Z 6 28 teeth
I stage
N9 Z 10
N 10 Z9
N10
Z 9 Z 10 Z 9 43 teeth
N9
N 13 Z 14
N 14 Z 13
N13
Z 14 Z 13 Z 14 0.576 Z 13
N 14
But
4.128 Design of Transmission Systems
Z 9 Z 10 Z 13 Z14
Z 13 Z 14 63 teeth
Z 13 0.576 Z 13 63
Z13 40 teeth
and
Z14 23 teeth
Similarly
N 11 Z 12
N 12 Z 11
N 11 1033
Z 12 Z 11 0.717 0.717
N 12 1440
But
Z11 Z 12 Z 13 Z14 63 Z 11 Z 12 63
and
Z12 63 36 27
Z12 27 teeth
27 20 4; 27 23 4
satisfactory
Design of Speed Reducers (Gear Boxes) 4.129
N max
n 1
N min
(i) C45 30
(ii) C14 25
6. Calculation of module:
(i) Find the torque for the gear
P 60
T
2 N
T 2T
Ft
r Zm
4.130 Design of Transmission Systems
Ft
m
m
b
where, m 10
m
F n Normal load
Design of Speed Reducers (Gear Boxes) 4.131
Ft
Fn
cos
(ii) Torque eq T eq
M 2 T2
P 60
T
2 N low
1/3
16 Teq
ds
16T eq
where,
d3s
(From point 4)
T 0.2d3s []
1/11
600
1.338
25
From PSG data book Page No. 7.20
N 11 450, N 12 600
Stage 1
N max 140
1.75 2
Ninput 80
N min 25
0.31 0.25
Ninput 80
Stage 2
N max 190
1.36 2
Ninput 40
Design of Speed Reducers (Gear Boxes) 4.133
N min 80
0.57 0.25
Ninput 40
Stage 1
N min 140
0.311 0.25
Ninput 150
N max 250
0.56 2
Ninput 450
3. Kinematic Arrangement
4. Calculate the No. of teeth of all the gears
Stage 3
1st pair: Maximum reduction from 80 rpm
corresponding gears are 13 and 14 on shaft 25 rpm.
Z 13 N14
Z 14 N13
20 25
; Z14 64
Z 14 80
Z 11 N 12 140
12 N 11 80
Z 11 1.75 Z 12
where, Z 11 Z 12 Z 13 Z14
1.75 Z 12 Z 12 20 64
4.134 Design of Transmission Systems
H 4 50
3 35
2 50
G
D
1 90
F
1 40
E
1 06
80
C
60
45
Sh a ft-1
S haft-3
S haft-2
Sh aft-4
3 3.5
Z12 31
Stage 2
1st pair: Maximum speed reduction from 140 to 80
rpm (corresponding gears are 9 and 10)
Assume Z9 20 (driver)
Z9 N 10
Z 10 N9
20 80
Z 10 140
Z10 35
Z7 N8 190
Z8 N7 140
Z 7 1.357 Z 8
where, Z 7 Z 8 Z 9 Z10
1.357 Z8 Z 8 20 35
Z8 24
Z7 1.357 24 32
Stage 1
1st pair: Maximum reduction from 450 to 140 rpm
(corresponding gears are 5 and 10)
Design of Speed Reducers (Gear Boxes) 4.137
Assume Z5 20 (driver)
Z5 N6
Z6 N5
20 140
Z 6 450
Z 6 65
Z3 N4 190
Z4 N5 450
Z 3 0.422 Z 4
where, Z 3 Z 4 Z 5 Z6
0.422 Z4 Z 4 20 65
Z4 60
Z3 0.422 60 25
Z1 N2 250
Z2 N1 450
Z 1 0.555 Z 2
where, Z 1 Z 2 60 25 85
Z2 55
Z1 0.555 55 30
5. Material Selection: C 45
4.138 Design of Transmission Systems
6. Calculation of module:
Torque at lowest speed 25 rpm by meshing gears 13
and 14.
60 3.25 10 3
T 14
2 25
1241.40 N m
T 2 T 14
Ft
r Z 14 m
. . Zm
. r 2
2 1241.40 10 3
64 m
38793.75
m
F t
module m
m
b
m 10 , 30 [for C 45 ]
m
m
38793.75 /m
10 30
129.31
m
m
Design of Speed Reducers (Gear Boxes) 4.139
129.31
m2
m
m 3 129.31
m 5.056 mm
Nearest value is 5 mm
Z1 Z2
Stage 1, a1 m
2
30 55
a1 5
2
a1 212.5 mm
Z7 Z8
a2 m
2
32 24
5
2
140 mm
Z11 Z 12
a3 m
2
54 31
5
2
4.140 Design of Transmission Systems
212.5 mm
b 10 5 50 mm
9. Length of shaft
L 860 mm (given)
Fn L
M
4
Ft 38793.75 /m
Fn
cos cos
Assume, 20
Fn 8256.6 N
8256.6 860
M 1.77 10 6 N mm
4
T eq
M 2 T214
1.77 10 62 1241.4 2
1.77 10 6 N mm
1/3
16 T eq
ds
P 60 3.25 10 3 60
Torque
2 N 2 450
T 69 N m
T 0.2 d 3s
1
69 10 3 0.2d3s 30
1
ds 22.57 mm or 23 mm
1
ds2 33.64 mm
ds 40.5 mm
3
Solution
1. Selection of spindle speed
N max
n 1
N min
1/17
17 650 650
35 35
1.1875
4.143 Design of Transmission Systems
2. Ray diagram
Formula: 2(1) 3(2) 3(6)
Stage 3
N max 280
2
Ninput 140
N min 35.5
0.253 0.25
Ninput 140
Stage 2
N max 280
1.186 2
Ninput 236
Design of Speed Reducers (Gear Boxes) 4.144
560
, 475
400
335
C
280
H F
236
G
200
E
170
140
D
118
B
100
85
71
60
50
42.5
Stage 1 Stage 2 Stage 3
35.5
A
RAY DIAG RAM for 18 Speed G ear Box
4.145
Z 1 =2 3 Z = 20
3
Driver 475 rpm 20 m m 20 mm 7b
1 3
4 Z 7 = 30
2 Z 5 = 25
a 1=
Z 9 =20
91 .5m m
Z 13 =6 6
Driven Driver 236 rp m
Z 11 =4 1
9
5
7 10 Z 1 5 =20
a 2=
6
8 1m m
15
10 m m 4b
Z 8 =25 16
Z 6 =29 11
Z 1 0 =34
Design of Transmission Systems
7b 14
D riven
Z 1 4 = 33
280 rpm
Stage 1 Stage 2 Z 1 2 =5 8
Stage 3
35.5 rpm
100 rpm
Kinematic Arrangem ent for 18 Speed G ear B ox Z 1 6 = 79
Design of Speed Reducers (Gear Boxes) 4.146
N min 140
0.59 0.25
Ninput 236
Stage 1
N max 280
0.59 2
Ninput 475
N min 236
0.49 0.25
Ninput 475
State 3
1st pair: Maximum reduction from 140 to 35.5 rpm
(Corresponding gears are 15 and 16)
Z 15 N 16
Z 16 N 15
20 35.5
Z 16 140
Z16 79
Z 11 N 12
Z12 N11
4.147 Design of Transmission Systems
Z 11 100
Z12 140
Z 11 0.714 Z 12
Z 11 Z 12 Z 15 Z 16
0.714 Z 12 Z 12 20 79
Z12 58
Z11 0.714 58 41
rd
3 pair: Speed Increases from 140 to 280 rpm.
Z 13 N 14
Z 14 N 13
Z 13 280
Z 14 140
280
Z 13 Z14 Z 13 2Z 14
140
where, Z 13 Z14 Z 15 Z 16
2Z 14 Z 14 20 79
Z14 33
Z 13 2 33
Z13 66
Stage 2
I pair: Maximum reduction from 236 to 140 rpm
(Corresponding gears are 9 and 10)
Assume, Z9 20 (driver)
Design of Speed Reducers (Gear Boxes) 4.148
Z9 N 10
Z 10 N9
20 140
Z 10 236
Z10 34
Z5 N6
Z6 N5
200
Z5 Z6
236
Z 5 0.847 Z 6
where, Z 5 Z 6 Z 9 Z 10
0.847 Z 6 Z 6 20 34
Z6 29
Z5 0.847 29 25
Z7 N8
Z8 N7
280
Z7 Z 8 Z 7 1.186 Z 8
236
Z 7 Z 8 Z 9 Z10
4.149 Design of Transmission Systems
1.186 Z 8 Z 8 20 34
Z8 25
Z7 1.186 25 30
Stage 1
1st pair: Maximum Speed Reduction from 475 to 236
rpm (Corresponding gears are 3 and 4)
Assume, Z3 20 (driver)
Z3 N4
Z4 N3
20 236
Z 4 475
Z4 40
280
Z1 Z 2 Z1 0.59 Z2
475
where,
Z 1 Z2 Z 2 Z4
0.59Z 2 Z 2 20 41
Z2 38
Z 1 0.59 38
Z1 23
Design of Speed Reducers (Gear Boxes) 4.150
5. Material Selection
Select 40 Ni2 Cr1 M0 28
P 60 6.75 10 3 60
(i) T 16
2 N 2 35.5
T 16 1815.71 N m
T 2 T16
Ft
16 r Z 16 m
2 1815.71 10 3 45967.34
79 m m
Ft
wkt, m
m
b
m 10 ; 100
m
45967.34 /m
45.96
m
10 100 m
45.96
m2
m
m 3 45.96
m 3.58 mm
4.151 Design of Transmission Systems
23 38
4 122 mm
2
For stage 2
Z5 Z 6
a2
2
25 29
4 108 mm
2
For stage 3
Z11 Z 12
a3 m
2
42 58
4 200 mm
2
110 18b
Fn L
M
4
Ft 45967.34 /m
Fn
cos cos 20
Assume 20
45967.34 /4
12.22 10 3 N
cos 20
12.22 10 3 830
M
4
M 2.53 10 6 N mm
Teq
M 2 T216
2.53 10 62 1815.71 10 32
6.40 10 12 3.29 10 12
Teq 3.11 10 6 N mm
1/ 3
16 T eq
ds
1/3
16 3.11 10 6
55
66.03 66 mm R 40 series
P 60 6.75 10 3 60
Torque
2 N 2 475
T 135.70 N m
T 0.2 d 3s
1
1/3
135.70 10 3
ds
1
0.2 55
ds 23.10 mm
1
25 mm R 40 series
P 60 6.75 10 3 60
Torque
2 N 2 236
273.12 N m
d s 29.17 30 mm R 40 series
2
Design of Speed Reducers (Gear Boxes) 4.154
P 60 6.75 10 3 60
Torque
2 N 2 140
460.41 N m
Solution
No. of speeds Z 6
N max
Z 1
N min
400
6 1
125
1.262
1.06
N 1 125 rpm
N 2 160 rpm
N 3 200 rpm
N 4 250 rpm
N 5 315 rpm
N 6 400 rpm
Structural formula
Z32 P1 3 X1 1
P1 P2 P2 2 X2 P2 3
Z P 1 X 1, P 2 X 2
3 1, 2 3
N max N min 1
Check Either 2 or
N input N input 4
N max 250 a s B
N min 125 as A
Design of Speed Reducers (Gear Boxes) 4.156
3 (1) 2 (3 )
D =710 rpm
710 rpm
400 rpm
315 rpm
B
250 rpm
200 rpm
C
160 rpm
125 rpm
3(1) Ray D iag ram 2(3) A
Z 7 = 28
STAG E I Z 9 = 24 S TAG E II
4.157
Z 5 =20
5
7 9
6
10
8
Z 3 =29
Z 1 =2 0
1
3 2
4
Driven
Z 8 = 63
Z 1 0 =6 7 Z 4 =23
Z 6 = 71 (3 15 rpm ) Z 2 = 32
(2 50 rp m ) (250 rpm ) (125 rpm )
(200 rp m )
Design of Speed Reducers (Gear Boxes) 4.158
N max N min 1
Check 2 and
N input N input 4
250 125 1
2 and
200 200 4
6 speeds 3 2 2 3 2 10 gears
Z 2 N o . of teeth on driven
Z2 N1
Z1 N2
N1
Z2 Z1
N2
200
20 32 teeth
125
4.159 Design of Transmission Systems
Z1 20 teeth, Z2 32 teeth
Since centre distance is same
Z 1 Z 2 Z3 Z 4 20 32 52
Z4 N3
and
Z3 N4
Z4 200
0.8
Z3 250
Z 4 0.8 Z3
Z 3 0.8 Z3 52
Z3 29 teeth
But Z 3 Z 4 52
Z4 23 teeth
Z6 N5
Similarly,
Z5 N6
Assume Z5 20 teeth
N5
Z6 Z5
N6
710
20
200
71 teeth
Z5 20 teeth, Z6 71 teeth
Z 5 Z 6 Z7 Z 8 91
Design of Speed Reducers (Gear Boxes) 4.160
Z 7 Z 8 91
Z8 N7
and
Z7 N8
Z8 710
Z7 315
Z8 2.253 Z 7
Z7 2.253 Z 7 91
Z7 28 teeth
and Z8 63 teeth
Z 5 Z 6 Z 7 Z 8 Z 9 Z10 91
Z 9 Z 10 91
Z 10 N9
But
Z9 N 10
710
Z 10 Z
250 9
Z 10 2.84 Z9
Z 9 2.84 Z 9 91
Z9 24 teeth
and Z 10 91 24 67
Z10 67 teeth
4.161 Design of Transmission Systems
To avoid interference
Z 7 Z 5 and Z 7 Z 9 4
28 20 and 28 24 4
Module calculation
The lowest speed is 125 rpm
5 10 3 60 P 60
T125 rpm
2 125 2 N
381.97 Nm
But
Torque F t r2
2
Z2 m 32 m
But r2 16 m
2 2
381.97 10 3 F t 16 m
2
381.97 10 3 23,873.12
Ft N
2 16 m m
Ft
But m
Mm
Design of Speed Reducers (Gear Boxes) 4.162
b
where m 10 (assume) from P.S.G. Data book, Pg.No.
m
8.14
a1 Material constant
30, for C 45
23873 12
m /10 100
m
23873.12
m2
m 1000
m 3 23.873
m 2.9 mm
~
3 mm (standard) from P.S.G. Data book, Pg.No. 8.2
we know b 10 3 m
b 10 3 30 mm
78 mm
Z 5 Z 6 m 20 71 3
a2 136.5 mm
2 2
4.163 Design of Transmission Systems
Length of shafts
Assume Distance between the gear and gear box wall
is to be about 10 mm. Distance between the adjacent
groups of gears is to be about 20 mm. Total length
requirement for 2 pairs group and 3 pairs group are to be
4b and 7b respectively.
Thus the length of the shaft is obtained as
L 30 10 4b 20 7b 10 30
(First 30 and last 30 mm are for bearings)
Put b 30 mm
we get L 430 mm
Length of shafts is L 430 mm
Problem 4.16: Sketch the arrangement of a six speed gear
box. The minimum and maximum speeds required are around
450 and 1400 rpm. Drive speed is 1440 rpm. Construct speed
diagram of the gear box and obtain various reduction ratios.
Use standard output speeds and standard step ratio. Calculate
number of teeth in each gear.
Solution
No. of speeds Z 6
N max
Z 1
N min
1400
6 1 1.254
450
1.12
N 1 450 rpm
N 2 560 rpm
N 3 710 rpm
N 4 900 rpm
N 5 1120 rpm
N 6 1400 rpm
Structural Formula
Z3 2
P1 P2
P 1 3; X1 1
P 2 2; X2 P1 3
Z P 1 X 1, P 2 X 2
3 1, 2 3
N max as B
4.165 Design of Transmission Systems
N max
Check 2
N input
900
2
710
N min 1
N input 4
450
0.25
710
6 speeds 3 2 2 3 2 10 gears
Kinematic diagram
Let Z1 No . of Teeth of Driver 20 teeth
N 1 710 rpm
N 2 540 rpm
Z2 N1 N1 710
But Z2 Z1 20
Z1 N2 N2 450
Design of Speed Reducers (Gear Boxes) 4.166
Input
D 1440 rpm
,,
1400 rpm
B2
E 1120 rp m
B1
900 rpm
D
B
710 rpm
C A2
560 rpm
A1
450 rpm
1 s t Stage 3(1) 2 nd S tage 2(3 ) A
Ray D iag ram
4.167
Z 7 =27
Z 9 =2 3
Z 5 = 20
5
7 9
6
10 Z 3 =2 9
8
Z 1 = 20
1
3 2
4
Z 8 = 33
Z 6 = 40 1120 rpm Z 10 =37 Driven
7 10 rp m 900 rp m
900 rp m Z 2 = 32
(450 rp m )
Design of Speed Reducers (Gear Boxes) 4.168
32 teeth
N3 710 rpm
N4 900 rpm
Z 1 Z 2 Z3 Z 4 20 32 52
Z 3 Z 4 52
Z4 N3 710
But Z 4 Z Z 4 0.788 Z 3
Z3 N4 900 3
0.8 Z 3
Z 3 0.8 Z 3 52 1.8 Z3 52
Z3 29 teeth
But Z 3 Z 4 52
Z 4 52 29 23 teeth
Z3 29 teeth, Z4 23 teeth
Similarly,
Z6 N5
Z5 N6
N5
Z6 Z5
N6
4.169 Design of Transmission Systems
Assume Z5 20 teeth
1440
Z6 20 40 teeth
710
and hence
Z5 20 teeth, Z6 40 teeth
Similarly
Z 5 Z 6 Z 7 Z 8 60
Z 7 Z 8 60
Z8 N7
Z7 N8
1440
Z8 Z7
1120
Z8 1.28 Z7
Z7 1.28 Z7 60
Z7 27 teeth
But Z 7 Z 8 60 Z 8 33 teeth
Z7 27 teeth, Z8 33 teeth
Since centre distance is same
Z 5 Z 6 Z7 Z8 Z9 Z10 60
Z 9 Z 10 60
Z 10 N9
But
Z9 N 10
1440
Z 10 Z Z 10 1.6 Z9
900 9
Design of Speed Reducers (Gear Boxes) 4.170
Z 9 1.6 Z9 60
Z9 23 teeth
Solution
N max 400 rpm
N min 20 rpm
Z No . o f speeds 14
N max
Z 1
N min
1 1
14
400
1.259
20
Motor speed I 970 rpm.
4.171 Design of Transmission Systems
Trail 1
N 1 20 rp m N 8 100 rpm
18 3 3 2 P1 3 X1 1
P1 P2 P 3
Z P 1X 1, P 2X 2, P 3X 3 P2 3 X 2 P1 3
31, 33, 29 P3 2 X 3 P 1P 2 9
Z 3 1, 3 3, 2 9 4
3rd Stage
N max 63 rpm
N min 20 rpm
N max
2
N input
N max 63
Check 1.575
N input 40 which is less than 2
satisfactory,
Take N input 40 rpm
2nd Stage
N max 160 rp m
N min 40 rpm
N max 160
1.6
N input 100 which is less than two
Ist Stage
For 1st stage, there is no need to check the condition
N max
2 . Therefore select Ninput as 400 rpm.
N input
Kinematic Arrangement
Draw the Kinematic arrangement for 18 speed gear
box.
In 3rd stage, 2 speeds are required – Two pairs of
gears required.
In 2nd stage, 3 speeds are required – Three pairs of
gears are required.
In 1st stage, 3 speeds are required – Three pairs of
gears are required.
III Stage
I Pair: Reducing speed
(O u tp ut)
4.175 Design of Transmission Systems
1
2
4
3
5
6
* **
8
7
10
9
11
16 14 12
*
13
15
Design of Speed Reducers (Gear Boxes) 4.176
Take Z 2 20 teeth
20 20
40 Z 1
40 20
Z1 40
20
Z1 40 teeth
Z2 20 teeth
Z 1 Z 2 40 20 60
63 Z 4 Z 3 Z4 60
40 Z 3 Z 3 1.575 Z 3 60
Z 4 1.575 Z 3 60
Z3 23.30 teeth
2.575
take Z 3 24 teeth
Z 4 60 24 36
Z3 24 teeth
Z4 36 teeth
4.177 Design of Transmission Systems
II Stage
1st Pair: Reducing speed.
40 Z6
100 Z5
Take Z 6 20 teeth
100 20
Z5 50 teeth
40
1st Pair Z5 50 teeth
Z6 20 teeth
Z 5 Z 6 Z 7 Z 8 50 20 70
Z7 Z8 70 ... (1)
Design of Speed Reducers (Gear Boxes) 4.178
160 Z 8
100 Z 7
70
Z7 26.92
2.6
Take Z 7 27 teeth
Z 8 70 27 43
Z7 27 teeth
Z8 43 teeth
N9 Z 10
Velocity ratio
N 10 Z9
Z 9 Z 10 Z 5 Z 6 50 20
80 Z 10
Z 9 Z 10 70 2
100 Z9
Z 10 0.8 Z 9 1
Z 9 0.8 Z 9 70
70
Z9
1.8
4.179 Design of Transmission Systems
Z 9 38.88 ; Z 10 70 39 31
Z9 39 teeth
Z10 31 teeth
Z 8 Z 6 43 20 23
Z 8 Z 10 43 31 12
Since (1) Z 8 Z 6 4
and (2) Z 8 Z 10 4
Z6 20 teeth Z9 39 teeth
I Stage
I Pair: Reducing speed.
100 Z 12
Assume Z 12 20 teeth ;
400 Z 11
20 400
Z 11 80 Teeth
100
Z11 80 Teeth
Z12 20 Teeth
N 13 Z 14
V.R Z 11 Z 12 80 20 100
N 14 Z 13
Z 13 Z 14 100
160 Z 14
400 Z 13
Z 14 0.4 Z 13 2
Z 13 0.4Z 13 100
Z 13 Z 14 100
100
Z 13 71.42 72
1.4
Z 13 72 teeth
Z 14 100 72 28 teeth
4.181 Design of Transmission Systems
II Pair
Z13 72 teeth
Z14 28 teeth
125 Z16 Z 15 Z 16 Z 13 Z 14 Z 11 Z 12
400 Z 15
77 23 100
Z 16 0.3125 Z 15,
Z 15 0.3125 Z 15 100
Z 15 76.19 77
Z15 77 teeth
Z16 23 teeth
To avoid interference,
Check 1 Z 14 Z12 4
2 Z 14 Z16 4
Z 14 Z8 Z4
Output speed (1) 400
Z 13 Z7 Z3
28 43 36
400
72 27 24
28 43 20
400
72 27 40
28 20 36
400
72 50 24
28 20 20
400
72 50 40
Z 14 Z10 Z4
Output speed (5) 400
Z 13 Z9 Z3
28 31 36
400
72 39 24
28 31 20
400
72 39 40
23 43 36
400
77 27 24
23 43 20
400
77 27 40
23 31 36
400
77 39 24
Z 16 Z10 Z2
Output speed (10) 400
Z 15 Z9 Z1
23 31 20
400
77 39 40
23 20 36
400
77 50 24
23 20 20
400 23.89 rpm
77 50 40 ... (12)
Z 12 Z8 Z4
Output speed (13) 400
Z 11 Z7 Z3
20 43 36
400
80 27 24
20 43 20
400
80 27 40
Z 12 Z10 Z4
Output speed (15) 400
Z 11 Z9 Z3
20 31 36
400
80 39 24
20 31 20
400
80 39 40
20 20 36
400
80 50 24
20 20 20
400
80 50 40
Given: N max
Z 1
N max 560 rpm; N input
560
N min 100 rpm; 16 1
100
No. of speeds Z 16
1.12
Structural formula
Z 16 4 2 2 P1 4 X1 1
P1 P2 P3
3 stages required. P2 4 X2 P1 4
3rd Stage
To select N input,
N max 250
1.25
N input 200
which is 2 Satisfactory.
N min 100
0.5
N input 200
2nd Stage
Select N input 280 rpm
N max 315
1.125
N input 280
1st Stage
In this stage, N input 560 rpm
Input
I B7 560
B6 500
D3
B5 450
D2
B4 400
H
D1
B3 355
G
B2 315
F D
B1 280
E C3
B 250
C
2
A7 224
C1
A6 200
C
A 5 180
A4 160
A3 140
A2 125
A1 112
A 100
st nd rd
1 Stage 4 (1) 2 S tag e 2(4 ) 3 Stag e 2 (8 )
4.189 Design of Transmission Systems
2
1
4
3
(1 00)
6
5
8
7
12 10
11 9
13
16 1 4
15
Design of Speed Reducers (Gear Boxes) 4.190
Locate I:
In the 3rd stage, above point (C); mark (D) after
four space intervals. i.e. at 315 rpm.
In the 2nd stage, above point (E); mark (F), (G),
(H) with one space interval.
Join CA; CB
100 rpm 250 rpm
From C 1
Join IF, FC 1 C 1A 1; C 1B 1
224 112 rpm 280 rpm
Join IG
From G
GC 2 250 GD 2 400
From C 2
C 2A 2 125 C 2B 2 315
Join I H
From H
HC 3 280 HD 3 450
From C 3
C 3A 3 140 C 3B 3 355
4.191 Design of Transmission Systems
Kinematic Arrangement
28 16
III Stage
Z 2 32 teeth
Z1 25 teeth
Z2 32 teeth
Design of Speed Reducers (Gear Boxes) 4.192
Z 1 Z 2 Z 3 Z4 25 32 57
57
Z 3 Z 4 57; Z 3 0.5 Z 3 57; Z3 3.8 teeth
1.5
Z 4 19 teeth
Z3 38 teeth
and Z4 57 38 19 teeth
II Stage
Z5 25 teeth
Z6 28 teeth
4.193 Design of Transmission Systems
But Z 7 Z 8 Z5 Z 6 25 28 53
Z 7 0.714 Z 7 53
Z7 31 teeth
Z8 22 teeth
63
Z 11 0.5 Z 11 63; Z 11 42 teeth
1.5
and Z 12 6 42 21 teeth
Z11 42 teeth
Z12 21 teeth
Z 14 Z 13 63
0.71428 Z 13 Z 13 63
63
Z 13 ~ 37
1.71428
Z 14 63 37 26
Z13 37 teeth
Z14 26 teeth
Z 14 N o. of teeth on driver
Z 15 0.633 Z 15 63 ;
Z 15 39
Z15 39 teeth
Z16 24 teeth
Solution
Given
N max 2000 rpm
P 6 kW
N max
Z 1
N min
2000
8 1
180
1.41
Design of Speed Reducers (Gear Boxes) 4.196
Structural formula
Z222
8 P 1, P 2, P 3
P 1 X 1, P 2 X 2, P 3 X 3
P1 2 ; P2 2 ; P3 2
X1 1 1
X2 P1 2
X3 P1 P2 2 2 4
U N o. of stages 3
N max
2
N input
800
2
560
N min 1
0.25
N input 4
180 1
0.25
560 4
Kinematic diagram
No. of gears required are
2 2 2 2 2 6 12 Gears
III stage
Speed of driven N 1 Z2
Speed of driver N 2 Z1
Let Z2 20 teeth
Design of Speed Reducers (Gear Boxes) 4.198
H
2 00 0
1 40 0
1 00 0
F D
8 00
E B
5 60
C
4 00
2 50
1 80
I S tag e II S tag e III S tag e A
2 (1) 2 (2) 2 (4)
R ay D iag ram
Z 1 2 = 20 Z 1 0 =1 8
4.199
12 10
Z 6 =2 7
11 9 Z 8 =2 0
8
6 Z 2 = 20
7
Z 11 = 29 Z 9 = 31 5
10 00 rpm D riven D river 560 rp m
80 0 rpm
2
I STA G E
1
Design of Transmission Systems
Z 5 = 22
10 00 rpm Z 7 =2 9
5 60 rpm 4
3
I I S TA G E
Driven
Z 3 = 34
800 rp m
180 20
560 Z 1
Z1 62 teeth
N3 Z4
Similarly
N4 Z3
Z1 Z2 Z3 Z4
20 62 Z 3 Z 4 Z 3 Z 4 82
800 Z 4
Z 4 1.42 Z 3
560 Z 3
Z 3 1.42 Z 3 82
Z3 34 teeth
and Z4 48 teeth
II stage
N7 Z8
N8 Z7
Assume Z8 20
560 20
800 Z 7
Z7 29 teeth
Similarly
N5 Z6
N6 Z5
Z 7 Z 8 Z5 Z6
29 20 Z 5 Z 6
4.201 Design of Transmission Systems
Z 5 Z 6 49
also
1000 Z 6
Z 6 1.25 Z 5
800 Z5
Hence
Z5 22 teeth
Z6 27 teeth
I stage
Z11 N 12
Z12 N 11
Assume Z12 20
1440 Z 11
1000 20
Z11 29 teeth
Similarly
Z 9 Z 10 Z11 Z 12
(i.e.) Z 9 Z 10 49
and
Z9 N 10 Z9 1440
Z 10 N9 Z 10 800
Z 9 1.8 Z 10
1.8Z 10 Z 10 49
Z10 18 teeth
Z 9 49 18
Z9 31 teeth
Design of Speed Reducers (Gear Boxes) 4.202
Given
I. Bottom Gear
N1 N8 Z2 Z7
5
N2 N7 Z1 Z8
Z2 Z7
5
Z1 Z8 ... (1)
4.203 Design of Transmission Systems
* * * *
Z2 Z5
3
Z1 Z6
... (2)
Z2 Z3
1.5
Z1 Z4
... (3)
Since the centre distance is same for all the gears,
Z 1 Z 2 Z 3 Z 4 Z5 Z6 Z7 Z 8
Design of Speed Reducers (Gear Boxes) 4.204
PCD PC D
2 144
Gear 2
1 Gear 2
But, Module m
PCD
Z
D
Z where Z No. of teeth.
D or PCD pitch circle diameter.
DmZ
mo dule Z 1 module Z2
144
2 Gear 2
1 Gear 2
module m 4 mm given
4 Z1 4 Z2
144
2 2
Z 1 Z 2 72 teeth
Z3 Z4
Z5 Z6
Z7 Z8
Let Z 8 20 teeth
Z 7 Z 8 72
Z 7 72 20
52 teeth
4.205 Design of Transmission Systems
Z7 52 teeth
Z8 20 teeth
Bottom Gear
From eq. (1),
Z2 Z7
5
Z1 Z8
Z2 Z8 20
5 5 1.923
Z1 Z7 52
Z 1 1.923 Z 1 72
72
Z1 24.63
2.923
Take Z 1 25 teeth ; Z 2 72 25
47 teeth
Z1 25 teeth
Z2 47 teeth
Second Gear
From eq. (2)
Z2 Z5
3
Z1 Z6
47 Z5
3
25 Z 6
Design of Speed Reducers (Gear Boxes) 4.206
1.596 Z 6 Z 6 72
72
Z6 27.73
2.596
Take Z 6 28 teeth
and Z5 72 28 44
Z5 44 teeth
Z6 28 teeth
Top Gear
From eq. (3)
Z2 Z3
1.5
Z1 Z4
47 Z3
1.5
25 Z 4
Z 3 Z 4 72 ... (9)
From eq. (8) and (9)
0.7978 Z 4 Z 4 72
72
Z4 40.04
1.7978
Take Z 4 40 teeth
4.207 Design of Transmission Systems
Z 3 72 40 32
Z3 32 teeth
Z4 40 teeth
Actual Speeds
Speed of driven N o. of teeth on driver
Spe ed of driver No. of teeth on driven
Top Gear
Speed of driven (output speed)
Z1 Z4
Speed of driver
Z2 Z3
(Assume speed of driver 2000 rpm )
25 40
Output speed for Top gear 2000
47 32
1329.78 rpm
Second Gear
Z1 Z6
Output speed for 2nd gear 2000
Z2 Z5
25 28
2000
47 44
676.98 rpm
Bottom Gear
Z1 Z8
Output speed for bottom gear 2000
Z2 Z7
25 20
2000
47 52
408.16 rpm
Design of Speed Reducers (Gear Boxes) 4.208
D 2 mZ 2 4 47 188 mm
D 3 mZ 3 4 32 128 mm
D 4 mZ 4 4 40 160 mm
D 5 mZ 5 4 44 176 mm
driven N1 100 rpm
D 6 mZ 6 4 28 112 mm
driver N2 160 rpm (input)
D 7 mZ 7 4 52 208 mm
D 8 mZ 8 4 20 80 mm
Sh iftin g leve r
En gagem en t G ear
d og s Se lector Fo rk
1 2 3 4 5 R
Dog D2
Dog D1
D og D 3
Fro m To
En gine D iffere ntial
M ain shaft
A P
Prim ary D1 F D2 J L D3 Idle r
D H N G ear
sha ft
C E M
G
B I
L aysh aft K
Fig.4.3 Con stant Mesh Gear B ox
are always in mesh (i.e), all the gear wheels are always
being meshed with their pair.
The general layout of constant mesh type is similar
to that of the sliding mesh, however it differs in the terms
of gear wheel type and wheel teeth design.
Constant mesh gear box uses double helical gears for
its transmission, the main benefit of double helical (or)
stronger helical gear is that it helps in “quieter (less noisy)
operation”
The helix arrangement on the teeth (or) the gear
tooth is always in contact with its pair which reduces the
chattering effect which is quiet common in case of straight
cut teeth (or) spur gear type.
Design of Speed Reducers (Gear Boxes) 4.210
Sh ell Vanes
C o re
C o re
R u nn er
H o using
,m peller
,nput Sh aft O utput S haft or R u nn er
O il C ircula tio n
Van es
E n gine
C ra nk
S h aft
H u bs C lutch
S ha ft
Applications
Fluid couplings are used in many industrial
applications involving rotational power in machine
drives.
Rail transportation and Hydraulic braking systems.
Automobile and Aviation systems.
P um p S tator Va nes
Turbine Turbine P um p
P um p
Turb in e H elping to R ota te Pum p
Turbin e S to pp ing P um p
Pu m p
Turbine
Pu m p(im pe llo r)
( Fixe d to H ou sing )
Stator
Fig.4.8 Torque Con verter Cut Away(Assemb ly)
5.1.1 Introduction
In a cam drive, there are two main components, cam
and follower. The cam acts as a driving member and is
made to have miscellaneous boundary (usually curved
shape) surface in order to transmit desired motion to the
corresponding follower (the driven member) by a direct
contact. The cam shape is like a disc with some projection
on its face. The cam transmits the desired motion (linear
or oscillatory) to the follower.
To an d fro mo tion
(b)
(a) plate cam (b) w edge cam
(or)
Radial cam w ith Translating follower.
(a) Fig.5.1
1. Base Circle
The smallest circle drawn to the cam profile from the
centre of rotation of cam. The base circle decides the size
of the cam drive.
2. Cam Profile
This is the boundary curve of the contact surface of
the cam with the follower.
3. Trace Point
It is the point on the follower for the purpose of
tracing the cam profile.
4. Prime Circle
It is the smallest circle drawn to the pitch curve from
the centre of rotation of the cam.
5. Pitch Curve
The imaginary curve obtained when the follower is
assumed to rotate the cam, keeping the cam fixed. It is the
path of the trace point.
Cams, Clutches and Brakes 5.5
Prim e Ra
circle
Rb
rp
Pitch Ba se
curve circle
9. Stroke
The maximum displacement of the follower from the
base circle of the cam.
1. Simple polynomial: y c n
2. Trigonometric curves
1. Simple harmonic
2. Double harmonic
3. Cycloidal.
Solution
Given Data:
n 2.4
2N
60
2 60
40 0.6981 rad . 6.283 rad/sec
180 60
10 c 0.6981 2.4
10
c 23.69
0.6981 2.4
dy d
Velocity c n
dt d t [Where t]
v c n n 1 2
2.4 1
v 23.69 6.283 2.4 30
180
v 144.39 mm/sec
d 2y
Acceleration c 2 n n 1 n 2
dt 2
2.4 2
2
23.69 6.283 2.42.4 1 30
180
Cam Curvature
1 d 2y
Flat follower P c Rb y 2 2
min
dt
Roller follower
2 32
1 dy
R p y2
dt
Pk 2
min
2 1 dy 1 d 2y
R p y 2 R b y 2
dt
dt 2
2N dy d 2y
; Velocity; A cceleration
60 dt dt 2
6’ f f’
5’ e e’
4’ d d’
25 3’ c c’
mm
b b’
2’
a a’
P
1’
0 1 2 3 4 5 6 6’ 5’ 4’ 3’ 2’ 1’ 0’
o
o =15 0 d 1 R d 2
Displacem en t Diagram
fh
Pitch circle radius R p
4.315 25
Rp 41.2 mm.
5
6
3’
R o ller 4’ 6 Tra nsitio n a nd
5’ Follow er 5 Pitch P oint (P)
4 2’
c
d 3
P
2
M otio n o f 1 b
e 0 1’
Follow er
6’ 1 50
o a
f o 0’
o 75
75 o
o
30 Pitch
Q
o o’ C ircle
60
Cam 0”
Pro file
o a’
1 20
Pitch
C u rve b’ 1”
2”
c’
f’
6” d’
e’ 3”
5”
4” o
(a) Pressure An gle Limited to Appro ximately 20
Cams, Clutches and Brakes 5.13
2
P m 20
h sin
150
Rp
p
2 cos 150 ra d
180
p
and m tan 1 cot
p
20 tan 1 cot
150 180 150
180
tan 20 1.2 cot 1.2 p
0.36397
cot 1.2 p 0.3033
1.2
1
0.3033
tan 1.2 p
1.2 p 73.12
p 60.03 61
2
60.93
25 sin
150
180
Rp 39.149 mm
60.93
2cos
150 180 h 25 mm
Take R p 40 mm
h
y 1 cos
2
25 61
1 cos 8.88 mm
2
150
180
Take y 9 mm
CAM PROFILE
Procedure
m =2 0
o
0 Pitch
0
15
C ircle
o
R P = 40 m m
6’ 30
f
O”
o Pitch
60 a’ C u rve
o
Cam 120 1”
Pro file
b’
2”
c’
f’
d’ 3”
e’
6”
4”
5”
o
(b) Pressure Angle Lim ited to E xactly 20
5.16 Design of Transmission Systems
when Acceleration is zero.
2
Cycloidal: When Acceleration is maximum.
4
Parabolic: When Acceleration is maximum.
2
r 4 Nose radius;
0 1 A to B Displacement
Flank y r 3 r 1 1 cos
Acceleration
y a 2r 3 r 1 c o s
when 0; a is max.
a max 2r3 r1
5.18 Design of Transmission Systems
Flank B N ose
r4 D
C2
r3
r5
A
2
r1
Base circle
1
1 2 B to D y r 4 r 1 r 5 r 4 cos 2
Nose
a 2r 5 r 4 c o s 2
Put 2
a min 2r5 r4
Cams, Clutches and Brakes 5.19
Line diagram
A B
r4
D
r3
C2
r
r5
3
O O D =r 5
1
Fig. 5.4 C1
a
y
Flank N o se
B
r4 D
y c2
y r4
A c2 D
r1 r3 2 r 3 =C B
L r5 CA
r1 (=O D )
r3
o o
1
1
B
A D
C2
c1
(b)
(a) o
c1
C 1 (c)
Fig. 5.6 Circular A rc Cam with Flat F aced Fo llo wer.
r2
D1
r2 B1 B1 s
D1
A1 S D
B D B
A1 r4
y
r4 c2
y
c2
A
A
r1
L rs r1 r 5 =O D
(=O D )
o o
(a)
(b)
Fig. 5.7 Tangent Cam with Ro ller F ollower
Cams, Clutches and Brakes 5.21
F
B1 r4
r2 s
D1
A1
B D
y
c2
A
r1 r3
o r5
Fig. 5.8 C1
C ircular A rc C am w ith R o lle r Fo llo w er
r 1 Least radius 50 mm
Lift 25 mm
C 1C 2 r 3 r 4
150 r 4 ... (1)
5.22 Design of Transmission Systems
O C1 r 3 r 1
150 50 100 ... (2)
O C 2 r 1 lift r 4
50 25 r 4
75 r 4
AOC 2 70, Therefore, C 2O C 1 110 ... (3)
Using Cosine Rule
C 1C 22 OC 21 O C 22 2O C 1 O C 2cos 110
1745 81.6 r 4
1745
r4 21.38 mm
81.6
To find 1,
Apply sine rule,
Cams, Clutches and Brakes 5.23
OC 2 C 1C 2 C 1C 2 r 3 r 4
sin 1 sin 110
= 150 - 21.38
53.615 128.62
= 128.62 mm
sin 1 sin 110
B
D
25
r4
=
ft
Li
0 C2
15
=
r3
-
70
r5
E
o
A 0
=7
2
50
o
11O
=
r1
O
C1
5.24 Design of Transmission Systems
53.615
sin 1 sin 110 0.3917
128.62
1 sin 10.3917 23
1 23
r 4 21.38 mm; r 5 75 mm
1 23
r1 = 5 0
=
O 70 o
11 0 o
r4 =
21 B
r3 = 47
15 o
0 C
2
=
23 o
C
1
Cams, Clutches and Brakes 5.25
Given Data:
4-stroke petrol engine;
r 4 Nose radius 3 mm
But r 3 r 1 OC 1 Calculate OC 1
5.26 Design of Transmission Systems
A
r1
=5 8 .5
O o
(18 0-5 8.5 )
r3
r5
B
r4
C2
1
D
C1
put 2 But r 5 r 4 O C 2
a 2r 5 r 4 Calculate OC 2
Step 1.
OC 2 r 1 lift r 4
18 10 3 25 mm
C 1C 2 r 3 r 4
OC 1 r 1 r 4
O C 1 18 3 O C 1 15
Cams, Clutches and Brakes 5.27
Su ctio n Valve TD C
O pen s
o
4
1 80 +5 0+ 4= 23 4 o
o
50
Su ctio n
Valve C loses
BD C
234
1
Speed of cam shaft speed of crank shaft.
2
1
(Therefore cam angle is also angle of crankshaft)
2
234
22 117
2
117
Cam angle for lift 2 58.5
2
5.28 Design of Transmission Systems
Simplify,
r 1 18 mm
O C 1 103.36 mm
r 4 3 mm
C 1C 2 O C 1 15 103.36 15
lift 10 mm
118.36 mm
Step 2.
To Find 1
Step 3.
r 3 O C 1 18
Acceleration is maximum
103.36 18
a max 2r 3 r 1
121.36 mm
2
2 80 121.36 18 N 80 rpm
60 1000
2N
2
7.254 m/sec 60
Cams, Clutches and Brakes 5.29
Step 4.
Retardation
2
2 2 80 25
a min O C2
60 1000
1.754 m /sec 2
Step 5.
m 250 gram
Procedure
Step 1.
From the given data, note down all the given
information like the load to be lifted, torque supplied, etc,
and then find the type of cam, follower and its motion
based on the lift, velocity and acceleration required. Also
select proper material to be used for cam and follower.
Step 2.
By assuming proper pressure angle, calculate the
prime circle radius of the cam.
Step 3.
Calculate the minimum radius of curvature of the
pitch curve by using formula (or) design chart and finalise
the radius of follower and base circle of cam.
Step 4.
Using lift and cam angles draw the displacement -
angle diagram and then draw the cam profile.
Step 5
Find the width of the face of cam based on the contact
strength of cam material.
Step 6.
Find the dimensions of the follower with respect to
their withstanding strengths, space limitation, etc.
Step 7.
Evaluate the spring parameter such as stiffness,
spring index and length by using suitable formulae.
Cams, Clutches and Brakes 5.31
Ca m Fo rce
N o rm al N 2
Pre ssure A ngle
Su rfa ce/Pitch
C u rve
A Rr y Ca m Fo rce F n
h
Fn Cos
C ir
R
ch
P it
Rb Rp
In itital Cam
Ba se Fo rce on th e guide,
Po int p rofile
C ircle F n Sin
1 dy
tan
R d
For parabolid,
harmonic and cycloidal
cams, the prime circle
radius can be evaluated Pitch
C u rve
using the formula assuming
maximum pressure angle as y’
dy
dt
max
tan max Rp
R p y
y e
tan
R 2p e 2 y
dy
Where y
d
1 d 2y
P C min R b y 2
dt 2
2 N dy d 2y
, velocity and Acceleration.
60 dt dt 2
Cams, Clutches and Brakes 5.35
F n E 1 E2 1 1
c 0.591
b [E 1 E 2] R r P Cmin
Note: Minus sign is used when the follower is in
contact with concave portion of the cam profile.
where,
Fn Normal force at the point of contact.
R ising
N 1 W
al
N1
rm
No
B F n cos
Fn
Fn
A N2
N 2
F n sin
Fig:5.11
Fv F n cos v
T
(here F
and the normal force F n is obtained by
Cams, Clutches and Brakes 5.37
W
Fn
2A B
cos h sin
B
Where
Co-efficient of friction.
A Overhang length.
B Follower bearing length.
Given data
h 25 mm
70 70 rad
180
Follower radius r r 20 mm
m 0.5 kg
5.38 Design of Transmission Systems
Solution
From P.S.G. Data book Pg. No.7.110 for cycloidal
cam, the rise ‘y ’ of the cam is given by.
h 1 sin 2
y
2
Differentiating we get the velocity (From P.S.G data
book Pg.No.7.110)
dy h 2
v 1 cos
d
when
0.25
25 1
y 2 sin 2
1
y 25 0.25 sin 2 0.25
2
y 25 0.25 0.00435
y 25 0.2456
y 6.14 mm
and
dy h
v 1 cos 2
d
Cams, Clutches and Brakes 5.39
2N
60
2 5000
60
523.59 ra d/sec
dy 25 523.59
[1 cos 2 0.25
d
70 180
13089.75
[1 0.2484]
1.221
10720.91 0.7516
8057.53 mm/sec
dy
d
Pressure angle tan
Rp y
But Rp y r
1 dy
tan
r d
or
1 dy
tan 1
r d
W.k.t
5.40 Design of Transmission Systems
R p R b Rr
80 20
100 mm
r 100 6.14 mm
r 106.14 mm
1
tan 1 8057.53
106.14
89.2
d 2y 2 h 2 2
A fmax 2
2
sin
d m ax
2 25 10 3 523.3 2
A f max sin 2 0.25
1.22172
28819.88 0.0273
788.53 m/s2
F 1 m f A f max
0.5 788.53
394.265 N
1
y 25 [0.75 sin 2 0.75]
2
25 0.7369
18.42 mm
F1
k
y
394.265
18.42
21.40 N/mm
Cam forces
F n max F s h k
25 21.40
535 N
When from downward these two forces donot reach
their maximum at the same time. Therefore it is necessary
to calculate both the forces and obtain their sum for
different values of
1. 0 ; y 0 ; Fs F1 0 ; 0
2. 0.25 ; y 6.14 mm
F s 6.14 21.40
131.39 N
and
F 1 394.265 N and
89.2
F 394.265 131.39
525.661 N
3. 0.375 , 18.15
1
y 25 0.375 sin 2 0.375
2
6.56 m
Cams, Clutches and Brakes 5.43
F s 21.40 6.56 m
140.384 N
d 2y 2
F1 m f 2
m f 2 h 2
sin 2
d
592.4 N
F 592.41 140.384
732.794 N
d 2y
4. 0.5, y 12.5 mm , 0
d
F s 12.5 21.46
267.5 N
F1 0
F F s F 1 0 267.5 N
F 267.5 N
dy 25
[1 c o s 2 0.5]
d 1.2217
20.46 [0.5030]
10.29 mm/ra d
r 100 12.5
112.5
5.44 Design of Transmission Systems
1
tan 1 10.29
112.5
5.22
1. F n 9 for 0
525.661 N
2. F n 37648.9 N for 0.75
cos 89.2
732.794 N
3. F n
cos 18.15
15128 for 0.375
267.5 N
4. F n
cos 5.22
268.61 N for 0.5
Thus we find
F n max 37648.9 N
Solution
W.k.t
2 3/2
1 dy
R p y2
P K min dt
2
2 1 dy 1 d 2y
R p y 2 R p y 2
dt dt 2
2
1 d 2y h
Also
2 dt 2 max
2
at
150
180
2.62 radian
1 dy
At , y 20 mm, a nd 0
dt
3/2
40 202 02
P K min
40 202 2 02 40 20 14.38
Assume
R p 40 mm
R r 16 m
P K min 48.4 mm
We find P K min R r
Solution
Calculate the minimum base circle radius R b
Rb Rp Rr
Given data
Radius of roller R r 6 mm
w.k.t
dy
dt
max 2h
tan max
R p y h
Rp 2
2 25
tan max
25
R p 2 60
180
60 3 60
3
2 25
tan 38
25
Rp 2 3
150
tan 30
R p 12.5
R p 48.6 mm
R b R p R r 48.6 mm 6 mm
R b 42.6 mm
Cams, Clutches and Brakes 5.47
2h
e
h
tan 25
2
e
R 2p 2
2 25
e
tan 25
25
48.62 e 2
2
47.75 e
0.4663
2361.9 e 2 12.5
24.75
5.2 CLUTCHES
5.2.1 Definition
A clutch is a device used to engage and disengage
the driving shaft to the driver shaft according to the
requirement. In case of automobiles, the clutch is required
during changing of gears. By operating a lever, the clutch
engages and disengages the driver and driven shafts. While
changing gears, the driven shaft should be disengaged from
the driving shaft.
5.48 Design of Transmission Systems
dx
p
r1
r2 r2 x
W
r1
Let,
W Axial thrust,,
p Intensity of axial pressure,
r1 External radius of friction disc
r2 Internal radius of friction disc.
r Mean radius of friction disc
Coefficient of friction
Ft Frictional torque transmitted by the clutch
W
Intensity of pressure p
r21 r22
2 r3 r3
Total frictional torque Ft W 2
1 2
3 2
r1 r2
Ft W r
... (1)
where r = mean radius of the friction surface
2 r31 r32
r
3 r21 r22
5.52 Design of Transmission Systems
1
p or p. x constant
x
pmax r2 C
C
or pmax
r2
pmin r1 C
or
C
pmin
r1
W
paverage
r21 r22
1
Total frictional torque Ft W r1 r2
2
Wr
Cams, Clutches and Brakes 5.53
r1 r2
2
(d) Axial thrust W 2 C r1 r2
In general
2 r31 r32
r mean radius for uniform pressure
3 r21 r22
1
r r2 ... for uniform wear
2 1
Note:
n n1 n2 1
the ratio of the mean radius to the face width as 4, (c) outer
and inner radii of the clutch plate. Take y for the shaft
Power 10 HP 7.36 kW
3 495000 kW kw
(a) Diameter of shaft d
N []
kw k1 k2 k3 k4
y 38 kgf/mm 2 ; FOS 2
y 1
2 FOS
38 1
9.5 kg f/mm 2
2 2
d
3 495000 7.36 2.82
900 950
2.29 cm o r 2.3 c m
d 23 mm
rm mean radius
rm
b (given)
4
[M t]
im
2 P b b r2m
Take P b 3 kg f/cm 2
71620 HP 71620 10
Mt 795.77 kg f c m
N 900
Design torque [M t] M t k
w 795.77 2.82 2244.07
2244 kg f cm
Mt
im
2 Pb b r2m
2244
2
rm
23 0.25 r2m
4
2244 4
r3m
2 3 0.25 2
rm
3
952.38117
rm 9.8 c m or 98 mm
Mean radius rm 98 mm
rm
ro r i
4
98
ro ri 24.5
4
ro ri
But rm 98
2
ro ri 98 2 196 ... (2)
By solving eq. 1 and eq. 2 we get ro 110.25 mm and
ri 85.75 mm
Inner radius of the clutch plate ri 85.75 mm
Outer radius of the clutch plate ro 110.25 mm
Problem 5.9: Design a suitable clutch for scooter of 150 C.C.
Axial thrust is to be provided by suitable helical springs. At
maximum torque, the power developed is 4 kW at 3200 rpm.
Space restricts the outer diameter of the clutch to be 150 mm
[May/June - 2008]
d0
The outer radius r0 75 mm
2
ri 0.8 r0
97400 kW
Transmitted torque M t
N
5.58 Design of Transmission Systems
97400 4
3200
121.75 kg f c m
i m1 m 2 1
[M t]
imin
2 P b b r2m
kw k1 k2 k3 k4
P b 3 kg f/cm 2
P a k P b 3 1 3 kgf/cm 2
75 60 15 mm 1.5 cm
[M t ] ro 75 mm (Given)
imin
2 Pb b r2m
and ri 60 mm
375 r1 r0
2 3 1.5 0.3 6.75 2 rm 2
0.97 75 60
67.5 mm
2
6.75 c m
Take imin 1
No. of plates m 1 m 2 i 1 1 1 2
C pmax ri 3 6
18 kg/cm
Given data
Power 30 kW
P 30 kW 30 10 3 W
0.25
Do
1.5
Di
Solution
Let ro & ri be the outer and inner radii respectively.
ro 1.5 ri
Now find
60 P 60 30000
T
2 N 2 1400
204.62 N m
204.62 10 3 N mm
w.k.t
T n W rm
Here,
Cams, Clutches and Brakes 5.61
W 0.63 r2i N
rm Mean radius
ri r o
rm
2
ri 1.5 ri
2
rm 1.25 ri
T n W rm
We have
1/3
204.62 10 3
ri
0.3937
ri ~
80 mm Di 160 mm
5.62 Design of Transmission Systems
And
ro 1.5 ri 1.5 80
ro 120 mm D o 240 mm
The axial thrust applied by the spring W
W 0.63 r2i
0.63 802
W 4032 N
Solution
Given data
Power P 50 kW ; Speed N 500 rpm
Assume service factor 1.25
Let P d Design Power
50 10 3 1.25
62500 W
Now calculate design torque that is to be transmitted.
60 P d 60 62500
T
2N 2 500
1193.66 N m
1193.66 10 3 N mm
Cams, Clutches and Brakes 5.63
Let,
60 N/mm2 (Assume)
Then
1/3
16T
d
1/3
16 1933660
d
60
1/3
30938560
d
188.49
d [164134.15 ]1/3
d 54.75
d 55 mm
Let
ri 2d 2 55
110 mm
165 mm
5.64 Design of Transmission Systems
W.k.t.
n n 1 n 2 1 5 6 1 10
Assume, 0.35
Now
T n Wrm
ri ro 110 165
rm 137.5 mm
2 2
T 1193660
W
n rm 10 0.35 137.5
W 2480.33 N
Now
W
pmax
2 r i r o r i
2480.33
2 110 165 110
b ro ri 165 110
b 55 mm
Thickness
t 5 mm (Assumed)
3. Face width 55 mm
4. Thickness 5 mm
P 30 kW ; N 1200 rpm
150
pmax 0.2 N/mm 2 ; 0.25 ; rmin 75 mm
2
97400 kW 97400 30
Mt
N 1200
2435 kg f cm
Tran smitted
M t 2435 kgfc m (or) M t 243500 N mm
torque
For uniform wear condition,
P max rmin C
C 0.2 75 15 N /mm
i4316
Torque transmitted [M t] i W rm
r2max 9070
Solution
Given data
pmax ri C
C 0.3 37.5 11.25 N/mm
Hence required operating force
W 2 C [ro ri]
2650.7 N
ro ri 75 37.5
rm
2 2
5.68 Design of Transmission Systems
and
75 37.5
T 0.1 2650.7 8
2
119.281 10 3 N mm
119.2 N m
2 NT
Power
60
2 750 119.2
60
9361.94 W
Power 9.36 kW
Problem 5.14: Find the torque that two surface of dry disc
clutch can transmit if the outside and inside lining diameter
are 120 mm and 70 mm respectively and the applied axial
force is 10 kN. Assume uniform wear and 0.4
(Apr/May - 2008 AU)
Solution
For uniform wear, [P max ri C ]
Given that
W 10 kN, ri 35 mm ; ro 60 mm
W
pmax
2 ri ro ri
Cams, Clutches and Brakes 5.69
10
2 35 60 35
1.8189 10 3 kN/mm2
p ri C (constant)
ro ri 60 35
rm 47.5 mm
2 2
T n p W rm
[np i no.of frictional surfaces]
380 Nm
b C o nical F riction
Su rfa ce
Sp rin g
r1
B
r2
Wa
D riving
sha ft
D rive n
D rive n sha ft
D rive n
sha ft
Let
r1 r 2
rm Mean radius of friction surface
2
S em i cone angle
1. Uniform pressure
2. Uniform wear
Cams, Clutches and Brakes 5.71
1. Uniform pressure
2 pn r31 r32
Frictional torque F t
sin 3 (1)
Frictio n
b surfac e
F= W n
r1
r r2
Wn
Wa
Fig. 5.1 4 Forces o n a F riction S urface
Normal face W n
pn 2r b
pn 2 rb sin (2)
r1 r2
But, sin
b
r1 r2 r1 r2
(or) b and r
sin 2
r1 r2 r1 r2
W a pn 2 sin
2 sin
5.72 Design of Transmission Systems
W a pn r21 r22
Wa
pn
r21 r22 (3)
Now, substitute the value of pn in eq (1)
2 Wa r3 r3
1 2
Ft
sin r2 r2 3
1 2
2 Wa r3 r3
1 2
3 sin 2 2 Wa
r1 r2 But Wn
sin
2 r3 r3
1 2
Ft W n 2 2
3 r1 r2
2. Uniform wear
Incase of uniform wear, the intensity of pressure
varies inversely with the distance (similar to the axial
clutch)
1
Px
x
C
Px
x (C a constant)
2 C r1 r2
2 2
Total frictional torque F t
sin 2 (4)
2 C r1 r2
Cams, Clutches and Brakes 5.73
Wa
C
2 r1 r2
2 Wa r2 r 2
1 2
Frictional torque F t
sin 2 r1 r2 2
W a r1 r2
sin 2
Wa
but W n
sin
r1 r2
Ft W n
2
r r2
Since, W n pn 2r b and r
2
F t pn 2r2 b
9400 kW
M t T ran smitted torque
N
97400 50
4058.33 kg f c m
1200
(o r) M t 405833 N mm
Frictional torque F t 2 pn b r2
pn 2r b
F aengage 2707.17 N
Solution
Given data
P 20000 Watts ; N 500 rp m ; 0.25
0.08 N/mm 2
s 40 MPa 40 MN/m 2
40 N/mm 2
Torque to be transmitted
60 P 60 20000
T
2 N 2 500
382 N m
382 10 3 N mm
Take d 40 mm
5.76 Design of Transmission Systems
Let
rm Mean radius
rm 4d assumed
rm 4 40 160 mm
Now
160
b 80 mm
2
20
b
ro rm sin
2
174 mm
b
ri r m sin
2
146 mm
Cams, Clutches and Brakes 5.77
T sin
pmax
ri r2o r2i
rm 5d 200 mm
b 100 mm
25
then
221 mm
ri 200 50 sin 25
179 mm
W a rm
T W n rm
sin
T sin
Wa
rm
3229 N
Fig.5.15
Cams, Clutches and Brakes 5.79
T Ff R n
where
Ff Frictional force
F f Fa Coefficient of friction
T Ff R n Fa R n
Fa
Rb
. .
. lR
Arm ature
Field C oil
H ub
Working:
Engagement: When the clutch is required to actuate,
current flows through the electromagnet, which produces a
magnetic field. The monitor portion of the clutch becomes
magnetized and set up a magnetic loop that attracts the
armature. The armature is pulled against the rotor and a
frictional force is generated at contact within a relatively
short time, the load is accelerated to match the speed of
the motor, there by engaging the armature and output hub
5.82 Design of Transmission Systems
Applications
Electromagnetic clutches are widely used because of
its compact nature; Some of the areas of applications are.
1. Machinery like lawnmover, copy machines,
conveyor drive etc.
2. Automobile: Helps the driver to shift gear, while
the vechile is in motion or running engine.
3. Locomotives: It is used in diesel locomotives.
Cams, Clutches and Brakes 5.83
5.3 BRAKES
5.3.1 Introduction:
Brake is a device which is used to stop the motion
of a machine or retard its motion. It is due to the friction
between contact surfaces.
. .
Braking torque = T B F tr R Nr [ . F t R N]
Case I
When the tangential braking force F t passes through
the fulcrum of the lever
N N
x x
Ft P
O O Ft P
Fulcru m RN r Fulcru m RN
r
2 2
Case II
When the tangential force F t passes through a
distance ‘a’ below the fulcrum.
x x
a O P a O P
Ft Ft
RN RN
r r
2 2
RN a R Nx Pl RN a Pl RN x
Pl R N x RN a Pl
RN
a x
Cams, Clutches and Brakes 5.87
TB R N r Pl
RN
x a
Plr Plr
TB TB
a x x a
Case III
When the tangential force F t passes through a
distance ‘a’ above the fulcrum.
x x
Ft Ft
a a
P P
O 2 R N r O 2 R N r
RN a Pl RN x RN a R Nx Pl
R N x R N a Pl Pl
RN
a x
5.88 Design of Transmission Systems
Pl TB R N r
RN
x a
Plr Plr
TB TB
x a a x
Case II (b) and Case III (a) are same
i.e., RN x R N a Pl
moment of frictional force
x a
RN
Ab
w 2rsin
Angle of contact
It is assumed that the normal reaction and frictional
force act at the mid point of the block; Usually the angle
of contact 2 is small i.e less than 60. When the value
of 2 is more than 60 2 60, then equivalent
co-efficient of friction w is used in torque equation.
4 sin
eq
2 sin 2
2 Angle of conta ct
Given:
2 120;
x 150 mm
5.90 Design of Transmission Systems
T B 80 N m
x
80 10 3 N mm
Diameter of drum O Ft P
Fu lcru m
d 300 mm (or) radius of RN
2
drum 150mm
Let P Force
required to operate the
(a ) Clo ck - W ise R otatio n
brake
Taking moments about O
RN x P l
Pl P 300
RN 2P
x 150
RN 2 P
4 sin
2 sin 2
1.03923
2.96042
0.351
Cams, Clutches and Brakes 5.91
80 103
P 759.7 N
105.3
Problem 5.18: The block brake is shown in the diagram;
Brake drum diameter provides a braking torque of 360 Nm,
and coefficient of friction is 0.3
Find (1) the force P to be applied at the end of the lever for
the clockwise and counter clockwise rotation of the brake drum.
2. The location of the pivot or fulcrum to make the self locking
for the clockwise direction.
2 00 6 00
50
O 1 00
Solution
1. (a) Consider clockwise direction
TB 360 N m
360 10 3 Nmm
300
r 150 mm
2
2 00 6 00
P
Ft
50
RN
O 1 00
Fig.5.3.4.
Braking torque TB Ft r
360 10 3 F t 150
F t 2400 N.
But F t R N
2400 0.3 R N
R N 8000 N
P 800 R N 200 Ft 50
P 1850 N
P 800 F t 50 RN 200
P 2150 N
Cams, Clutches and Brakes 5.93
200 600
P
Ft
50
100 O RN
P
Ft
x
O RN
100
F t x RN 200
5.94 Design of Transmission Systems
P 450 F t 50 RN 200
But P 700 N
3,15,000 50 F t R N 200
2 00 m m 2 50 m m
P
50 mm 7 00 N
O
Fig.5.3.13.
Cams, Clutches and Brakes 5.95
200 m m 250 m m
P
Ft
50 700 m m
RN
But F t RN
we know 0.35
F t 0.35 R N
R N 1726 N
F t 604.109 N
250
604.109 75513 Nmm
2
75.513 Nm
P 450 F t 50 RN 200
200 m m 250 m m
Ft
50 P= 70 0N
RN
R N 1448.27 N
F t 506.89 N
250
But Braking Torque TB F t r 506.89 63.36 Nm
2
a F a F
O
O
T2 A B T1 A B
L L
T1 T2
B ra ke d ru m B ra ke d ru m
S h aft S h aft
B a nd B a nd
Fig.5.2 0(a) C lockw is e D irectio n
Let
F Force applied at the end of the lever
T1 Tension on tight side of the band
Angle of lap
Coefficient of friction
r Brake drum radius
T1
Ratio of tensions e
T2
t
r
2
Braking torque on the drum TB T1 T2 re
(Considering thickness of band)
Consider clockwise rotation, taking moments about
fulcrum ‘O’
5.98 Design of Transmission Systems
Then, F l T1 a
T1 a
F
l
Consider anti-clockwise rotation, taking moments
about fulcrum ‘O’
Then,
F l T2 a
T2 a
F
l
where a perpendicular distance from O to the line of
action
l length of the lever
Note 1
2 NT B
P
60
P 60
T B Braking torque
2 N
Note 2
To find width of steel band
Then, T 1 t b t Newtons
A
F A
F
b b
T2 a a
O B C T1 O
B C
L T1 L T2
M M
Ba nd Ba nd
Bra ke drum Bra ke drum
Sh aft Sh aft
T2 Tension on slackside
5.100 Design of Transmission Systems
F Applied force
F l T1 b T 2 a
Fl T 2a T 1b
... (1)
For anti-clockwise rotation,
F l T2 b T 1a
F l T1a T2b
... (2)
When the frictional force helps to apply the brake it
is called self energizing brake.
Note 1
T 2 a T 1 b or T 1 b T2 a
(or)
Cams, Clutches and Brakes 5.101
T2 b
T1 a
T1 a T2 b or T2 b T 1 a
T1 b
(or)
T2 a
Note 2
If length of OB is greater than OA, then the force
F must act in the upward direction to apply brake.
Note 3
If the length OB is less than OA, then force F
must act in the downward direction in order to
apply brake. T 1 and T2 remain same.
Problem 5.20: A differential band brake shown in the
diagram has a width of 80 mm and thickness of 2 mm. The
permissible tensile stress in the band material is limited to 60
N/mm2. The Coefficient of
friction is 0.25 between drum
a F
and the friction lining. The 50 b
A 2 00
brake drum diameter is O
T2 B C
500 mm.
T1
Calculate for clockwise
direction
(a) Tension in the band
o
2 20
B ra ke d rum
(b) Actuating force
(c) Braking torque B and
self-locking or not.
5.102 Design of Transmission Systems
Given data:
b 80 mm ; t 2 mm ; t 60 N/mm 2
T2
A F
a
50 b
T2 O C
2 00 B
8 00
T1
F 800 T 1 200 T 2 50
1481 N m
Cams, Clutches and Brakes 5.103
Clockwise rotation
T2 b
T1 a
T2 3676
0.3829
T1 9600
b 200
4
a 50
T2 b
Since
T1 a
0.3829 4
Solution:
Given data
Load 50 kN 50 10 3 N
o
2 40
6 50
5 50 m m
mm
T2
F
2 10
L oa d T1 O
45
Fig.
1 50 0
4.188 rad
0.25
Step 1
Find braking torque
T B 50 10 3 N 225 mm
T B 11250 10 3 Nmm
T B 11250 N.m
Cams, Clutches and Brakes 5.105
Step 2
Find Tension T1 & T 2
o r T1 2.849 T2 ...(1)
Now,
TB T1 T2 r
T 1 T 2 34,615.4 N ...(2)
Comparing and solving both equation 1 and 2, we get
T 1 53336.5 N and
T 2 18721.14 N
Step 3
Thickness of band brake
t 0.005 D
0.005 650
t 3.25 mm
T1
t
wt
53,336.5
60 N/mm 2
w 3.25
w 273.5 mm
Step 4
Calculate the bearing pressure
T1
P max
w .r
53,336.5
273.5 325
P m ax 0.599 N/mm 2
Step 5
Force applied at the end of lever.
F 1500 T1 45 T2 210
F 1020.85 N
Cams, Clutches and Brakes 5.107
Solution:
Given data
T B 900 N m
0.3
10 a
0
m
m
D F
5 00 m m
T1 O b C
8 0m m
T2
o
2 40
Fig.
5.108 Design of Transmission Systems
OB l 500 mm 0.5 m
OC b 80 mm 80 10 3m
OD a 100 mm 0.1 m
240 240
180
4.188 rad
Step 1
Braking torque is given 900 N m
Step 2
Tension of tight and slack side.
T1
e0.3 4.188 3.5136
T2
T1 3.5136 T2 ...(1)
Also
TB T1 T2 r
T1 T2 3000 ...(2)
Comparing and solving equation (1) and (2) we get
T 1 4193.48 N
T 2 1193.50 N
Cams, Clutches and Brakes 5.109
Step 3
Taking moments about the fulcrum O, we get
F 0.500 T1 0.100 T 2 80 10 3
F 0.5 323.868
Solution
Given data
Angle of contact 2 16
8
d 600 mm 0.6 m
or r 300 mm 0.3 m
5.110 Design of Transmission Systems
D N
900 m m
O A
a B
40
T1 mm b
150 m m
T2
F = 2 50 N
r
D rum
Fig.
t 75 mm 0.075 m
Force F 250 N
OD a 40 mm 0.04 m
OA b 150 mm 0.15 m
OB l 900 mm 0.9 m
1. b > a.
n
T1 1 tan
T2 1 tan
12
T1 1 0.3 tan 8
T2 1 03 tan 8
T1
2.7524
T2
T1 2.752 T2
...(1)
Now taking moments about O.
F l T 1 a T2 b
T1 5636 N and
T2 2048 N
5.112 Design of Transmission Systems
Now
Maximum braking torque TB
d 2t
T B T 1 T 2
2
0.6 2 0.075
5636 2048
2
1345.5 N m
II. Find Angular retardation of drum
T B I mk 2
2.07 rad/s2
III. Time taken by the system to come to rest from the
speed of 300 rpm.
Initial angular speed
2N
i
60
2 300
31.4 rad/s
60
Final angular speed f 0 rad/s
Now
w.k.t
f i t
31.4
t
2.07
t 15.2 sec
Cams, Clutches and Brakes 5.113
Note
4 sin
2 sin 2
TB Ft Ft r
1 t
2
where F t and F t are braking forces on two blocks and
1 2
Solution
Given data
TB 1500 10 3 N mm
2 110 110 1.919 rad
180
5.114 Design of Transmission Systems
S S
3 00
Ft
2
o o
110 110
RN R N1
2
Ft 2 50
O2 O1
40 40 Fig.
Since 2 60 ;
0.4584
Cams, Clutches and Brakes 5.115
Ft
1
But RN
1
705.37 F t
1
F t 0.78 S Newtons
1
Ft
2
S 550 160 F t 250 545.37 F t
2 0.4584 2
F t 1.4272 S Newtons
2
Braking torque T B F t F t r
1 2
S 3398 Newtons
Ft
1 2650.4
RN 5782 N
1 0.4584
Ft
2
RN 10579.4 N
2
Ab b 2rsin
RN
Pressure
Ab
10579.4
0.5 R N RN
b 2r sin 2 1
11515
b
0.5 2 200 sin 55
b 64.6 mm
Solution
1. Relation between friction and Normal forces
Cams, Clutches and Brakes 5.117
S S
FL2 1 60 m m
o
110 RN
1
o
RN 110
2
F L1
1 60 m m
O1 O2
60 60
Fig.
Ft
RN
e
4 sin
But e
2 sin 2
since 0.3, 2 110 1.919
180
110
4 0.3 sin
e 2 0.3437
1.919 sin 110
Ft
1
RN
1 0.3437
5.118 Design of Transmission Systems
R N 2.91 F t
1 1
Similarly RN 2.91 F t
2 2
(ie)
320S 65 F t 465.5 F t
2 2
320S 400.5 F t
2
Ft 0.799 S
2
320 S 473 F r
F t 0.6 S
1
S 1426.4 N
Ft Fl
2
Wear ratio is
Ft Fr
1
Cams, Clutches and Brakes 5.119
Ft Fl
2 0.799 S
1.33
Ft 0.6 S Fr
1
3316.5 N
R N R nr 2.91 F r
1
2.91 0.6 S
A 2r sin b
204.78 b mm 2
R nl 3316.5
P Unit bearing pressure
A 204.78 b
16.19
N /mm 2
b
16.19
10 6 N/m2
b
5.120 Design of Transmission Systems
V rubbing velocity
Dn 250 10 3 650
60 60
8.508 m/s
16.19
10 6 8.508 1000000
b
b 137.74 mm
Let
R o tation
F F
r
D ru m
L in ing
a
c
O1 O2
Fig. 5.22
coefficient of friction
J polar moment of inertia of the brake drum Kg m.sec 2
t
5.122 Design of Transmission Systems
0.116 fo r steel
pm b r a
sin m r cos 1 cos 2 4 cos 22 cos 21
1 pm b r a 1
1 sin 2 sin 22
2 sin m 2 2
Mn Mf
F
C
M n M f
F
C
M npm M f pm
M n and Mf
pm pm
Cams, Clutches and Brakes 5.123
Braking torque
cos 1 cos 2
M t b r2 pm pm
sin m
Note 1
Note 2
o
o 30
30
F F
R
1 50 o
1 20
o 1 20
1 77
1 25 R
o
30
o 30
Fig.
5.124 Design of Transmission Systems
Solution
Assume that the maximum normal pressure will occur
between the lining on right hand shoe and the brake drum.
m max 90
a 125 mm
C 177 mm
r 150 mm
Given data
b 60 mm
0.35
p 1.2 N/mm 2
pm b r a
Mf r cos 1 c o s 2 4 cos 22 cos 21
sin m
125
cos 2120 cos 20
4
Cams, Clutches and Brakes 5.125
pm b r 1
Mn 2 1 sin 21 sin 22
2 sin m 2
1
675000 2.09 [0 0.866 ]
2
1706000 N mm
Mn Mf 1706000 673312.5
F
C 177
5834.39 N
r2 pmax b cos 1 c o s 2
M t
R sin m
561093.75 pm
1421666.66 pm
M n M f
For left shoe, F
C
Torq ue on th e p m
M tL MtR
le ft hand shoe pmax
283500 1.858
1.2
438952.5 N mm
438.9525 N mm
Therefore,
The to taltorque
283500 438952.5
capacity of the brace
M t 722452.5 N mm
722.4525 Nm
Cams, Clutches and Brakes 5.127
Alternately
Refer PSG data book, page No 7.99
c o s 1 cos 2
Braking torque b r2 p m p m
sin m
c o s 0 c o s 120
0.35 60 150 2 1.2 1.858
sin 90
472500 0.5 3.058
722452.5 N mm
M t 722.452 Nm
Solution
Given data
Diameter 300 mm 0.3 m
b 32 mm 0.032 m
0.32
1000 10 3 N /m 2
5.128 Design of Transmission Systems
o
27
F A F
1 00
0
15
O o
1 26
112
O1
O2
B
50 50
27
o Fig.
2 126
126
180
2.199 rad
90
Cams, Clutches and Brakes 5.129
OO 1
OB 2 BO 21
112 2 50
2
122.65 mm
1 pmax b r OO1 1
Mn 2 1 sin 2 1 sin 2 2
2 sin 2
1 0.3
1000 10 3 32 10 3 0.12265
2 2
1
[2.199 0 sin 0 sin 2 126]
2
787.27 N m
pmax b r OO1
Mf r cos 1 cos 2 c os 2 2 cos 2 1
sin 4
0.3
0.32 1000 10 3 32 10 3
2
1
0.3 0.12265
2 [cos 0 c o s 126 4
[cos 2 126 c o s 0]
304.174 N m
5.130 Design of Transmission Systems
M n Mf
F
l
787.27 304.174
0.112 0.100
2278.75 N
2
0.3
0.32 1000 10 3 32 10 3 cos 0 cos 126
2
365.83 N m
7.813 10 3 pmax
and
Cams, Clutches and Brakes 5.131
3.042 10 4 pmax
M N M f
F
l
2
3 3 0.3
0.32 445.04 10 32 10 c o s 0 cos 126
2
162.8 N m
T T B TB
365.83 162.8
528.64 N m
o
30
F F
1 00 .9 1 25 R
o
1 20
8 6.6
50 50
o
Fig. 30
Solution
Assume that the maximum normal pressure will occur
between the lining on right hand shoe and the brake drum.
For right hand shoe
m max 90
Also given
b 40 mm ; 0.32
pmax 1 N/mm 2
0.32 1 40 125
Mf 125 cos 0 c o s 120
sin 90
100
cos 2 120 c o s 2 0 ]
4
240000 Nmm
1 40 125 100 1
120 180 2 sin 2 0 sin 2 120
2 sin 90
1
250000 2.09 0 0.866
2
630750 Nmm
5.134 Design of Transmission Systems
Mn Mf
F
C
630750 240000
F
187.5
2084 N
Braking Torque
cos 1 cos 2
br 2 pm pm
sin m
cos 0 cos 120
0.32 40 1252 1 pm
sin 90
pm is unknown (i.e.) Max. pressure on left shoe
Hence
Similarly
M n pm
Mn 630750 pm
P max
Mn Mf
F
C
630750 pm 240000 pm
2084
187.5
pm 1
Cams, Clutches and Brakes 5.135
Braking Torque
cos 0 cos 120
0.32 40 1252 i 1
sin 90
600000 Nmm 600 Nm
m .k2
k radius of gyration
5.136 Design of Transmission Systems
1 2
Q t
2
t time in seconds
2 n 2 J
where Hg heat generated per operation k.cal
1800 427
Cams, Clutches and Brakes 5.137
OP e Centre distance
90
2
Z 2
2 2Z
Cams, Clutches and Brakes 5.139
s c l)
D i ee
e n Wh
iv a
Dr nev
e
(G
R
wd
e B
o
90
3
O
D riving D isc
(or) C rank r
R
1 sin cos cos
1 2
e Z
where R Radius of Geneva wheel.
h e sin c o s 1 e sin 1
Z Z Z
R e cos 2
Z
5.140 Design of Transmission Systems
h
(or) sin cos 1
e Z Z
The pin enters the Geneva wheel tangentially with
no shock. i.e., The centre lines of the slot and crank must
be mutually perpendicular at engagement and at
disengagement.
Z 2
2 2Z
tr Z2
t 2Z
w here tr resting time, seconds.
2N
where, rad /sec
60
Z No. of slots
P
P
d R
e A
A
90 o
B
r
e
r
Fig.5.24
sin
tan
1 cos
cos
1 2 cos 2
dmax
1
To avoid the wheel overhanging the bearing,
dW
2 1 sin
e Z
Non-interference of Geneva wheel shaft-with driving
disc (or) The shaft of the driving disc does not interfere
with the geneva disc, the following condition has to be
satisfied.
d
2 1 cos
e Z
o
20
88
1 25
A
Fig.5.25
c o s
d
1 2 cos 2
5.144 Design of Transmission Systems
1.7372
10.06 rad/sec
0.1725
13.313
448.25 rad/sec 2
0.0297
Solution:
Refer PSG Data book page No. 7.81
Given data:
r
sin sin
e Z
r
sin
e Z
Cams, Clutches and Brakes 5.145
r
e
sin
Z
50
e centre distance 100 mm
180
sin
6
e 100 mm
r 50
But, sin 0.5
e 100
sin 1 0.5
30
R
radius ra tio cot
r
1 50
R r c o t 50 86.6025 mm
tan tan 30
h Slot length r R e
50 86.6025 100
h 36.6025 mm
dw
2 1 sin
e Z
180
dw 2 100 1 sin
6
5.146 Design of Transmission Systems
dw 100 mm
180
Z 2 6 2 240
Z 6
Indexing time ratio
30 60
2 2
60
0.333
180
Z2 62
Resting time tn t 0.6 0.4 sec
Z2 62
Cams, Clutches and Brakes 5.147
1. Material:
Z 6 to 8
12 to 20
16 to 25
3. Values of p - linear unit pressure - P/b kgf/cm
P
p where P Peripheral force (or)
b
5.148 Design of Transmission Systems
G
P
o
90
D
t
b
a1
(a) (b)
b
P e1
h
a P
x
(c) (d)
Fig.5.26
P 2M t
b
p Zm
3 Mt
4. Module: m 2
Z [ b ]
Other Dimensions
a m; h 0.75m ; bm
5. Bending moment M b P h
Design of Pawl
M b P e1
1
6M b
1 P
Total stress
2 xb
bx
3 P b
Dia. of the pawl pin d 2.71 a
2 [ ] 2
b
1
Solution:
Given data:
1800 kg f cm
5.150 Design of Transmission Systems
Step 1:
Mt
2
3
and [b] 450 kgf/c m2
Z [b]
for ratchet
3 1800
2 0.8925 c m
18 2.5 450
Take m 1 cm or 10 mm
a m 1 cm;
h 0.75 m 0.75 c m
b m 2.5 1 2.5 cm
Step 2:
2M t
Peripheral force P But D Zm
D
2 1800
200 kg f
18 1
Step 3:
P 200
Linear unit pressure 80 kg f/cm 2
b 2.5
Cams, Clutches and Brakes 5.151
Step 4:
Refer PSG databook Page No. 7.85 Calculation of
diameter of pawl pin
y
P b [b]
d 2.71 a1 FOS
2[b] 2 for C45 steel (Pawl)
y 36 kgf/mm 2
3 200 25
d 2.71 6 Take FOS 5
2 7.2 2
36
17.228 mm [ b]
5
Take d 18 mm 7.2 kgf/ mm 2
Refer table (P.No. 7.86)
of PSG Data book
a1 6 mm
b 2.5 cm = 25 mm
Step 5:
Checking stress for pawl
6M b1 P M 1 Pe1
[b]
bx 2 x.b e1 a 1 cm 10 mm (assume)
6 2000 200 M b 20010
2
1
25 10 10 25
2000 kg f mm
4.8 0.8
x a 1 cm 10 mmassume
5.6 kgf/ mm 2
b 2.5 c m 25 mm
2
7.2 kgf/ mm
Design is safe
Two Marks Question and Answers TM.1
Chapter - I
1. Flat belt
2. V-belt
3. Round belt.
1.2 What are the commonly used belt materials?
1. Leather
2. Cotton or Canvas
3. Rubber
4. Nylon core
5. Balata
6. Fabric.
1.3 State Law of Belting
The law of belting states that the center line of the
belt as it approaches the pulley must lie on a plane
perpendicular to the axis of that pulley, or must lie in the
plane of the pulley, otherwise the belt will run off from the
pulley.
where
2 = 40
o
Fa bric and
W ru bb er co ve r
x
Fa bric
T C o rds
R u bb er
b
2
T1 sin
e
T2
P given power in kW
F a service factor
1. Roller Chains
2. Bushed Chains
(a) Simpler
(b) duplex
(c) Triplex.
TM.10 Design of Transmission Systems
Chapter - II
Pressure angle
14.5 20
Z min (Theoretical) 32 17
Z min (Practical) 27 14
1. Involute
2. Cycloidal
Chapter - III
3.1 State the use of bevel gears. (Apr/May 2008)
F r Fttan c o s
F a F ttan sin
2M t
Ft ;
d
av
M t torque on bevel gear
F t bm b Y
Metallic Materials
Chapter - IV
N 1 first speed,
N2 N1
N3 N2
Two Marks Question and Answers TM.31
Z 3 1, 2 3 x
1 60 0
1st 2nd E C
1 25 0
The No (3) indicates D
1 00 0
No. of speeds. The No.
B
inside the bracket indicates 8 00
No. of spaces in speed
6 30
diagram.
A
5 00
1 St S tag e Second Sta ge
Two Marks Question and Answers TM.33
(iii) 2 2 3 scheme
1.12 1.12
1.12 1.4
skip 2 speeds
N 1 18 rpm
N 2 25 rpm
N 3 35.5 rpm
N 4 50 rpm
N 5 71 rpm
N 6 100 rpm
Two Marks Question and Answers TM.37
Z4
Z6 Z2
D rive r
D rive n
Z3
Z5 Z1
N max N min 1
2 and
N input N input 4
If it is not possible
N max N input
keep
N input N min
(Or)
N max N input
keep
N input N min
Chapter - V
5.1 What is a cam?
Cam is a mechanical member having miscellaneous
contour surface which transmits a desired motion to a
follower by direct contact. With help of cam, it is very easy,
accurate and efficient to produce a motion with required
velocity and acceleration.
5.2 Give the list of types of cams used in industries.
The common types of cams used in industries are :
(1) Wedge cam (2) Radial cam (3) Globoloidial cam
(4) Cylindrical cam (5) Spherical cam (6) 3-dimensional cam
(3D) and (7) Inverse cam.
5.3 Give some applications of cams.
Cams are used in wide variety of machines such as,
packaging machines, can making machines, wire forming
machines, IC engines, machine tools, computing
mechanisms, mechanical and electronic computers, etc.
TM.40 Design of Transmission Systems
W W n 1 c o t
Planing machine
Hoisting machine
Bearing machine
Index
B Differential Band brake, 5.99
Based on Hertz Method, 3.64, Double shoe brake, 5.113
3.192 Dynamic Effects (Dynamic
Basic Curves, 5.6 Tooth Load), 2.19
Bevel Reducer, 4.212
E
Bevel Gear Nomenclature, 3.4
Efficiency of Worm Gearing,
Brake friction materials, 5.83
3.157
Brakes, 5.83
Electromagnetic clutch, 5.80
Bush chain, 1.120
C F
Cam Profile Layout, 5.31 Factor of Safety, 2.25
S W
Screw or Skew gears, 3.214 Wear Tooth Load, 2.21, 2.127
Sheave materials, 1.114 Wear Strength of Helical Gears,
Silent chains, 1.120 2.127
Simple band brake, 5.96 Wire Ropes, 1.91
Simple Harmonic Motion SHM, Worm Reducer, 4.211
5.16 Worm Wheel, 3.153, 3.192